Patent Abstract:
Pillar delivery films for vacuum insulated glass units. The delivery films include a support film or pocket tape, a sacrificial material on the support film, and a plurality of pillars. The pillars are at least partially embedded in the sacrificial material or formed within sacrificial material molds, and the sacrificial material is capable of being removed while leaving the pillars substantially intact. In order to make an insulated glass unit, the delivery films are laminated to a receptor such as a glass pane, and the support film and sacrificial material are removed to leave the pillars remaining on the glass.

Full Description:
BACKGROUND 
     Windows are poor thermal insulators and contribute significantly to building heat loss and energy inefficiency. The need to meet green building standards is driving the adoption of energy efficient insulated glass units including vacuum designs. A vacuum insulated glass unit  10  is shown in  FIGS. 1 and 2 . Unit  10  includes two panes of glass  11  and  12  separated by a vacuum gap. Pillars  14  in the gap maintain the separation of glass panes  11  and  12 , which are hermetically sealed together by an edge seal  13 , typically a low melting point glass frit, surrounding the pillars. Manufacturing vacuum insulated glass units efficiently and cost effectively can present challenges, particularly with selection of suitable pillars, placement of the pillars, and sealing the glass panes together with the vacuum gap. Accordingly, a need exists for improved ways to make and install pillars for vacuum insulated glass units. 
     SUMMARY 
     A pillar delivery film, consistent with the present invention, includes a support film, a sacrificial material layer on the support film, and a plurality of pillars. Each pillar is at least partially embedded in the sacrificial material layer, which is capable of being removed from the pillars while leaving the pillars substantially intact. 
     Another pillar delivery film, consistent with the present invention, includes a support film, a plurality of molds on the support film, and a plurality of pillars located in the molds. The molds are composed of a sacrificial material, which is capable of being removed from the pillars while leaving the pillars substantially intact. 
     A pillar delivery pocket film, consistent with the present invention, includes a support film having a plurality of pockets formed within it and a plurality of pillars located in the pockets. The support film is composed of a sacrificial material, which is capable of being removed from the pillars while leaving the pillars substantially intact. 
     Another pillar delivery pocket film, consistent with the present invention, includes a support film having a plurality of pockets formed within it, a sacrificial material located within the pockets, and a plurality of pillars at least partially embedded in the sacrificial material in the pockets. The sacrificial material is capable of being removed from the pillars while leaving the pillars substantially intact. 
     A method for transferring pillars from a delivery film to a receptor surface, consistent with the present invention, includes providing a delivery film having a support film, a sacrificial material on the support film, and a plurality of pillars at least partially within the sacrificial material. The delivery film is laminated to a receptor surface with the pillars facing the receptor surface. The support film is removed while leaving the pillars on the receptor surface and at least a portion of the sacrificial material on the pillars. The sacrificial material is then removed while leaving the pillars remaining and substantially intact on the receptor surface. 
     A method for making a delivery film having pillars and transferring them to a receptor surface, consistent with the present invention, includes providing a support film with a releasable surface. A plurality of pillars are molded on the releasable surface of the support film using a mold applied to the releasable surface, and the mold is removed from the releasable surface while leaving the pillars substantially intact. The pillars are then transferred from the support film to a receptor surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are incorporated in and constitute a part of this specification and, together with the description, explain the advantages and principles of the invention. In the drawings, 
         FIG. 1  is an exploded perspective view of a vacuum insulated glass unit; 
         FIG. 2  is a side sectional view of a vacuum insulated glass unit; 
         FIG. 3  is a diagram of a pillar delivery film for transfer to a sacrificial material layer; 
         FIG. 4  is a diagram of a pillar delivery film for transfer to a sacrificial material layer; 
         FIG. 5  is a diagram of a pillar delivery film and method for transfer directly to glass; 
         FIG. 6  is a diagram of a pillar delivery film and method for transfer to a sacrificial material layer; 
         FIG. 7  is a diagram of a pillar delivery film and method having a sacrificial material mold on a support film; 
         FIG. 8  is a diagram of a pillar delivery film and method for transfer to a sacrificial material layer on a support film; 
         FIG. 9  is a diagram of a pillar delivery film and method for transfer to a sacrificial material layer on a support film; 
         FIG. 10  is a diagram of coated pre-formed pillars; 
         FIG. 11  is a top view of pocket tape for delivering pillars; 
         FIG. 12  is a side sectional view of a portion of the pocket tape; 
         FIG. 13A  is a side sectional view of pocket tape having pre-formed pillars; 
         FIG. 13B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 13A ; 
         FIG. 14A  is a side sectional view of pocket tape having cured form-in-place pillars; 
         FIG. 14B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 14A ; 
         FIG. 15A  is a side sectional view of pocket tape having cured form-in-place pillars with adhesive; 
         FIG. 15B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 15A ; 
         FIG. 16A  is a side sectional view of pocket tape having cured form-in-place pillars with retention rings; 
         FIG. 16B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 16A ; 
         FIG. 17A  is a side sectional view of sacrificial pocket tape having cured form-in-place pillars; 
         FIG. 17B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 17A ; 
         FIG. 18A  is a side sectional view of carrier film and sacrificial pocket tapes having cured form-in-place pillars; 
         FIG. 18B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 18A ; 
         FIG. 19A  is a side sectional view of a pocket tape having cured form-in-place pillars in sacrificial pockets; 
         FIG. 19B  is a perspective view of the pillar resulting from the pocket tape of  FIG. 19A ; 
         FIG. 20  is a diagram of a pillar delivery film and method using a strippable tool; 
         FIG. 21  is a diagram of a pillar delivery film and method using a strippable tool with a sacrificial material layer; 
         FIG. 22  is a diagram of a pillar delivery film and method using a rotary tool; and 
         FIG. 23  is a diagram of a pillar delivery film and method using a strippable skin. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention include pillar delivery films and methods that can be used to provide the pillars required for fabrication of vacuum insulated glass units. The delivery films contain the pillars, and the methods can use the films to place the pillars on glass panes. One method involves mechanically depositing the pillars onto a pocket film or a film with a releasable surface and lamination transferring the pillars onto glass. Another method involves molding the pillars in place on a pocket film or a film with a releasable surface and mechanically transferring the pillars to glass. Another method involves molding the pillars in place on a pocket film or a film with a releasable surface and lamination transferring the pillars onto glass. The mechanical transfer of pillars, referred to as pick and place, can use robotics for the movement and placement of the pillars. The mold in place of the pillars and lamination transfer of them are described below. The methods can also deliver the edge seal in the glass units. The delivery films and methods can make use of lamination transfer films. 
     Examples of pillars for vacuum insulated glass units are described in U.S. Patent Application Publ. No. 2015/0079313, which is incorporated herein by reference as if fully set forth. Examples of lamination transfer films are described in U.S. Patent Application Publ. No. 2014/0021492, which is incorporated herein by reference as if fully set forth. 
       FIG. 3  is a diagram of a pillar delivery film with a sacrificial material layer for transfer to glass. The delivery film includes a support film  16 , a sacrificial resin material  17  forming molds, and form in place pillars  18 . The pillars can optionally include a pre-formed pillar body  15 . 
       FIG. 4  is a diagram of a pillar delivery film with a sacrificial material layer for transfer to glass. The delivery film includes a support film  19 , a sacrificial resin material  20  can be a continuous or discontinuous layer on support film  19 , pre-formed pillars  21 , and an optional functional layer  22  on or around the pillars. As illustrated, pillars  21  can be on or at least partially embedded within material  20 . The pillars can optionally include pre-formed pillar bodies  15 . 
       FIG. 5  is a diagram of a section of a pillar delivery film and method for transfer directly to glass. The delivery film includes a support film  24  having a mold  25 . The mold is filled with a curable pillar resin  26  to form a filled mold on the support film (step  30 ). Alternatively a preformed pillar may be inserted into the mold before or after the curable resin fill. The support film is laminated to glass  27  (step  31 ), and the film and glass laminate is cured (step  32 ). Film  24  with mold  25  is removed (step  36 ), resulting in pillar  26  on glass  27 . Alternatively, a molded pocket tape  28  can be used. Pocket tape  28  is filled with a curable pillar resin to form pillar  26  (step  33 ). The filled pocket tape  28  is laminated to glass  27  (step  34 ), and tape and glass laminate is cured (step  35 ). Pocket tape  28  is removed (step  36 ), resulting in pillar  26  on glass  27 . 
       FIG. 6  is a diagram of a section of a pillar delivery film and method with a sacrificial material layer for transfer to glass. Mold  41  can optionally be on mold support film  40 . The mold is filled with a curable pillar resin  42  to form a filled mold (optionally on mold support film  40 ) (step  50 ). Mold  41  (or optionally mold support film  40 ) is laminated to transfer film  44  having a sacrificial material layer  43  (step  51 ), and the mold (optionally be on mold support film  40 ) and transfer film  44  laminate is cured (step  52 ). Mold  41  or optionally be on mold support film  40  is removed (step  56 ), resulting in pillar delivery film comprising pillar  42  on transfer film  44  with sacrificial material  43  between them. Alternatively, a molded pocket tape  45  can be used. Pocket tape  45  is filled with a curable pillar resin to form pillar  42  (step  53 ). The filled pocket tape  45  is laminated to transfer film  44  having sacrificial material layer  43  (step  54 ), and pocket tape and transfer film  44  laminate is cured (step  55 ). Pocket tape  45  is removed (step  56 ), resulting in pillar delivery film comprising pillar  42  on transfer film  44  with sacrificial material  43  between them. 
       FIG. 7  is a diagram of a section of a pillar delivery film and method having a sacrificial material mold on a support film. The delivery film includes a mold support film  60  having a sacrificial material mold  61 . The mold support film  60  may be the sacrificial mold  61 . Mold  61  is filled with a curable pillar resin  62  to form a filled mold on mold support film  60  (step  70 ). The resin material is cured (step  71 ), and uncured pillar resin is deposited on the cured resin material (step  72 ). Mold support film  60  is laminated to glass  63  (step  73 ), and the film and glass laminate is cured (step  74 ). Mold support film  60  is removed, leaving sacrificial material mold  61  on resin pillar  62  (step  75 ). The sacrificial material is baked out (step  79 ), resulting in pillar  62  on glass  63 . Alternatively, mold support film  60  is laminated to glass  63  without the uncured pillar resin (step  76 ), and the film and glass laminate is cured (step  77 ). Mold support film  60  is removed, leaving sacrificial material mold  61  on resin pillar  62  (step  78 ). The sacrificial material is baked out (step  79 ), resulting in pillar  62  on glass  63 . 
       FIG. 8  is a diagram of a section of a pillar delivery film and method for transfer to a sacrificial material layer on a transfer film and lamination to glass. A support film  80  includes a release surface or coating  81 . Using a continuous cast and cure process, a pillar  82  is formed on support film  80  (step  90 ), and support film  80  with pillar  82  is laminated to a transfer film  83  having a sacrificial material coating  84  (step  91 ). Support film  80  is removed, transferring pillar  82  to transfer film  83  (step  92 ). An optional adhesive  85  can be applied to pillar  82  (step  93 ). Transfer film  83  is laminated to glass  86  (step  94 ), and transfer film  83  is removed (step  95 ). Sacrificial material  84  is removed (step  96 ), resulting in pillar  82  on glass  86  with optional adhesive  85 . As illustrated, pillars  82  can be partially embedded within optional adhesive  85 . 
       FIG. 9  is a diagram of a section of a pillar delivery film and method for transfer to a sacrificial material layer on a support film. The delivery film includes a support film  100  with a release surface or coating  102 . Using a continuous cast and cure process, a pillar  103  is formed on support film  100  (step  110 ) with a pillar land  106  between pillars, and an adhesive  104  is deposited on pillar  103  (step  111 ). Support film  100  with pillar  103  is laminated to glass  105  (step  112 ). Support film  100  is removed (step  113 ), resulting in removal of pillar land  106  and transfer of pillar  103  to glass  105  with adhesive  104 . 
       FIG. 10  is a diagram of coated pre-formed pillars. A pre-formed pillar  120  is coated in a wet or dry coating process (step  123 ) to form a coating  121  surrounding pillar  120 . The coated pillar can then be transferred to glass  122  using, for example, the methods described above. Additional functional layers can also be optionally added to the coated pillar. Coating  121  can include, for example, an adhesive coating, an silsesquioxane precursor with nanoparticles, or a polymer derived ceramic. 
       FIG. 11  is a top view of pocket tape  130  for delivering pillars. Pocket tape  130  typically includes holes  131  to engage machine gears. Material pockets  132  are formed in pocket tape  130 .  FIG. 12  is a side sectional view of a portion of the pocket tape  130  having pockets  132 . Pocket  132  includes a film portion  133  and a pocket portion  134  for using in forming, transferring, and delivering, pillars. 
       FIGS. 13A-19A  are side sectional views of various pocket tapes used to form pillars, and  FIGS. 13B-19B  are perspective views of the resulting pillars.  FIG. 13A  is a side sectional view of a pocket tape  140  having pre-formed pillars  141  ( FIG. 13B ).  FIG. 14A  is a side sectional view of a pocket tape  142  having cured form-in-place pillars  143  ( FIG. 14B ).  FIG. 15A  is a side sectional view of a pocket tape  144  having cured form-in-place pillars  145  with an adhesive  146  ( FIG. 15B ).  FIG. 16A  is a side sectional view of a pocket tape  147  having cured form-in-place pillars  148  with adhesive  151  and adhesive retention rings  149  to limit the lateral spread of the adhesive ( FIG. 16B ) and a liner  150 .  FIG. 17A  is a side sectional view of a pocket tape  151 , formed from a sacrificial material, having cured form-in-place pillars  152  ( FIG. 17B ).  FIG. 18A  is a side sectional view of carrier film tape  153  and a sacrificial pocket tape  155  having cured form-in-place pillars  154  ( FIG. 18B ).  FIG. 19A  is a side sectional view of a pocket tape  156  having cured form-in-place pillars  157  in pockets formed from a sacrificial material  158  ( FIG. 19B ). 
       FIG. 20  is a diagram of a section of a pillar delivery film and method using a strippable tool  160  composed of a strippable film molds  161 . The delivery film includes a support film  162  having a sacrificial material  163 . Strippable tool  160  is laminated to support film  162  to create molds (step  170 ), and a curable pillar paste  164  is coated onto support film  162  (step  171 ), creating curable pillar  164 A and land  164 B. The filled support film  162  is cured (step  172 ), and an adhesive  165  is coated onto cured pillar  164  (step  173 ), creating an adhesive coating  165 A on the cured pillar  164 A and an adhesive coating  165 B on the cured land  164 B. Strippable tool  160  is removed (step  174 ), taking with it cured land  164 B and adhesive  165 B, resulting in zero land pillar transfer film having pillar  164 A on sacrificial material  163  and adhesive  165 A. 
       FIG. 21  is a diagram of a section of a pillar delivery film and method using a strippable tool  180  composed of a strippable film molds  181  with a sacrificial material layer  183 . The delivery film includes a support film  182 . Strippable tool  180  is laminated to support film  182  (step  190 ), and a curable pillar paste  184  is coated onto support film  182  (step  191 ), creating curable pillar  184 A and land  184 B. The filled support film  182  is cured (step  192 ), and an adhesive  185  is coated onto cured pillar  184  (step  193 ), creating an adhesive coating  185 A on the cured pillar  184 A and an adhesive coating  185 B on the cured land  184 B. Strippable tool  180  is removed (step  194 ), taking with it cured land  184 B and adhesive  185 B, resulting in a zero land pillar transfer film having pillar  184 A and sacrificial material  183  on support film  182  and adhesive  185 A on pillar  184 A. 
       FIG. 22  is a diagram of a pillar delivery film and method using a rotary tool having an opaque perforated rotary mold tool  200  and curing units  201 . The delivery film includes a support film  204  having a sacrificial material  205 . A pillar material  206  is applied to support film  204  through perforated rotary mold tool  200  and cured by curing units  201  (step  210 ), resulting in formed pillars on support film  204  when removed from perforated rotary mold tool  200  (step  211 ). An adhesive  207  is coated on pillar  206  (step  212 ), resulting in zero land pillar transfer film having pillar  206  on sacrificial material  205  and support film  204  and with adhesive  207 . 
       FIG. 23  is a diagram of a section of a pillar delivery film and method using a strippable skin, which is a type of strippable tool. The delivery film includes a structured film mold  220  with a strippable skin  222  or a replicated resin mold  221  on film  220  with strippable skin  222 . A curable pillar paste  223  is coated onto the mold film  220  (step  230 ), creating curable pillar  223 A and land  223 B, the filled mold film  220  is cured (step  231 ), and an adhesive  224  is coated on cured pillar  223  (step  232 ), creating an adhesive coating  224 A on the cured pillar  223 A and an adhesive coating  224 B on the cured land  223 B. Strippable skin  222  is removed (step  233 ), taking with it cured land  223 B and adhesive  224 B, resulting in a zero land pillar transfer film having pillar  223  on support film  220  and with an adhesive  224 . 
     In the fabrication processes described above, additional or supplemental steps can be used within the described steps. In the processes described above, or other processes of the present invention, the sacrificial material can be removed by being cleanly baked out or by being otherwise capable of removal. The term “cleanly baked out” means that the sacrificial material can be removed by pyrolysis or combustion without leaving a substantial amount of residual material such as ash. In some of the side sectional views of the delivery films described above, only one mold and corresponding pillar are shown for illustrative purposes only. The delivery films typically include many of the molds and pillars for delivery of the pillars to vacuum insulated glass units. 
     Exemplary materials for the processes described above are provided in the Examples. Exemplary materials for the pillars for the vacuum insulated glass units include the following: ceramic nanoparticles; ceramic precursors; sintered ceramic; glass ceramic; glass frit; glass beads or bubbles; metal; or combinations thereof. 
     EXAMPLES 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 Materials 
               
             
          
           
               
                 Abbreviation or  
                   
                 Available 
               
               
                 Trade Designation 
                 Description 
                 from 
               
               
                   
               
               
                 FILTEK Supreme+  
                 paste 
                 3M Company,  
               
               
                 5032W 2009-04 
                   
                 St. Paul, MN 
               
               
                 QPAC 40  
                 poly(alkylene carbonate)  
                 Empower Materials, Inc., 
               
               
                   
                 copolymer 
                 New Castle, DE 
               
               
                 QPAC 100 
                 poly(alkylene carbonate) 
                 Empower Materials, Inc., 
               
               
                   
                 copolymer 
                 New Castle, DE 
               
               
                 QPAC 130 
                 poly(alkylene carbonate) 
                 Empower Materials, Inc., 
               
               
                   
                 copolymer 
                 New Castle, DE 
               
               
                 T50 
                 silicon release liner 
                 Solutia Inc.,  
               
               
                   
                   
                 St. Louis, MO 
               
               
                   
               
             
          
         
       
     
     Example 1 
     Replicated Mold of Sacrificial Material 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1,3-dioxolane to produce a final weight percent of 30% QPAC 40. The coating solution was hand coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicone release liner in a notch bar coater. Approximately 50 milliliters of the coating solution was applied to the T50 backside and pulled through a notch bar coater set with a gap of 0.024 inches. The coating was dried at ambient for 1 hour. 
     The coated film was placed on a hotplate coating side up and held at 50° C. until heated. A tool containing square protrusions on a 0.132 cm pitch was placed onto the coated film, protrusion side down. Individual square posts on this tool tapered at 6 degrees from 296 um at the base to 227 um at the top, and were 305 um tall. A 4.6 kg weight was placed onto the top of the tool, embossing the coating. The tool was allowed to contact the film at temperature for 5 minutes. The weight was removed from the tool and the assembly was removed from the hotplate, and allowed to return to room temperature. The tool was then removed. The coated film now contained wells in the coating that corresponded to the protrusions on the tool. 
     The wells in the film were then filled with FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with a spatula. The filled sample was then laminated to a clean glass slide at room temperature with a silicone hand roller. The resulting laminate was then cured under germicidal lamps for five minutes. The T50 liner was then removed, leaving cast posts attached to the glass slide, surrounded by the sacrificial mold. 
     Example 2 
     Replicated Mold of Sacrificial Material with Adhesive 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1,3-dioxolane to produce a final weight percent of 30% QPAC 40. The coating solution was hand coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicone release liner in a notch bar coater. Approximately 50 milliliters of the coating solution was applied to the T50 backside and pulled through a notch bar coater set with a gap of 0.024 inches. The coating was dried at ambient for 1 hour. 
     The coated film was placed on a hotplate coating side up and held at 50° C. until heated. A tool containing square protrusions on a 0.132 cm pitch was placed onto the coated film, protrusion side down. Individual square posts on this tool tapered at 6 degrees from 296 um at the base to 227 um at the top, and were 305 um tall. A 4.6 kg weight was placed onto the top of the tool, embossing the coating. The tool was allowed to contact the film at temperature for 5 minutes. The weight was removed from the tool and the assembly was removed from the hotplate, and allowed to return to room temperature. The tool was then removed. The coated film now contained wells in the coating that corresponded to the protrusions on the tool. 
     The wells in the film were then filled with FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with a spatula. The resulting laminate was then cured under germicidal lamps for five minutes. A second layer of FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with a spatula, leaving a thin layer of uncured FILTEK Supreme+ paste on top of the cured layer, imparting adhesion to the sample. 
     The sample was then laminated to a clean glass slide at room temperature with a silicone hand roller. The resulting laminate was then cured under germicidal lamps for five minutes. The T50 liner was then removed, leaving cast posts attached to the glass slide, surrounded by the sacrificial mold. 
     Example 3 
     Particle Delivery Film 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1-3 dioxolane to produce a final weight percent of 5% QPAC 40. The coating solution was delivered at a rate of 30 cm 3 /min to a 10.2 cm (4 inch) wide slot-type coating die. After the solution was coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, the coated web traveled approximately 2.4 m (8 ft) before entering a 9.1 m (30 ft) conventional air floatation drier with all 3 zones set at 65.5° C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10 ft/min) to achieve a wet coating thickness of about 80 micrometers. 
     A piece of the coated film slightly larger than 6 in×6 in was placed on a hotplate held at 50° C. Grade 36+ shaped abrasive particles prepared according to the disclosure of U.S. Pat. No. 8,142,531 having a side length of about 0.8 mm and about 0.2 mm thick, and a sidewall angle of 98 degrees. The particles were pressed into the heated film in a grid with 2 cm spacing, creating a particle delivery film. The particle delivery film was removed from the hotplate and brought to room temperature. 
     The cooled particle delivery film was laminated at 230 F, coating and particle side down to a 0.125 inch thick 6 in×6 in section of glass using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. The T50 liner was then removed, leaving the particles arranged on the substrate. 
     Example 4 
     Particle Delivery Film with Integrated Edge Seal 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1-3 dioxolane to produce a final weight percent of 5% QPAC 40. The coating solution was delivered at a rate of 30 cm 3 /min to a 10.2 cm (4 inch) wide slot-type coating die. After the solution was coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, the coated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m (30 ft) conventional air floatation drier with all 3 zones set at 65.5° C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10 ft/min) to achieve a coated film with a wet coating thickness of about 80 micrometers. 
     A slurry was prepared consisting of glass particles and QPAC 40 in MEK. A screen-print mesh was prepared by masking a 5.75 in×5.75 in square with tape on the top of the screen. A second solid square 5.25 in×5.25 in was created with tape and centered in the first square to create a square opening in the mesh 0.25 in wide. A section of the coated film larger than 6 in×6 in was placed under the screen, and the screen pressed and held against the coated film with weights. The prepared slurry was forced through the opening in the screen-print mesh with foam applicators. The screen was removed, and the slurry was allowed to dry overnight at room temperature, creating an edge seal delivery film. 
     A piece of the edge seal delivery film slightly larger than 6 in×6 in was placed on a hotplate held at 50° C. Grade 36+ shaped abrasive particles prepared according to the disclosure of U.S. Pat. No. 8,142,531 having a side length of about 0.8 mm and about 0.2 mm thick, and a sidewall angle of 98 degrees. The particles were pressed into the heated film in a grid with 2 cm spacing, creating a particle delivery film. The particle and edge seal delivery film was removed from the hotplate and brought to room temperature. 
     The cooled particle and edge seal delivery film was laminated at 230° F., coating and particle side down to a 0.125 inch thick 6 in×6 in section of glass using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. The T50 liner was then removed, leaving the particles arranged on the substrate, and the edge seal arranged around the perimeter of the glass. 
     Example 5 
     Landless Replication Via Mask Method 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1-3-dioxolane to produce a final weight percent of 5% QPAC 40. The coating solution was delivered at a rate of 30 cm 3 /min to a 10.2 cm (4 inch) wide slot-type coating die. After the solution was coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, the coated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m (30 ft) conventional air floatation drier with all 3 zones set at 65.5° C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10 ft/min) to achieve coated film with a wet coating thickness of about 80 micrometers. 
     A 2 mil perforated film was prepared by laser cutting (LaseX, Inc., White Bear Lake, Minn.) 500 micron diameter holes spaced on 2 cm centers into an 0.008 inch polypropylene film. The perforated film was laminated at 230° F., coating side down to a section of the coated film using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. 
     The wells in the film were then filled with FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with the edge of a glass microscope slide. The resulting film was then cured under germicidal lamps for five minutes. 
     The perforated film was peeled off of the substrate, leaving a particle delivery film that contained particles of cured FILTEK Supreme+ paste in the size and position of the holes in the perforated film. 
     The cooled particle delivery film was laminated at 230° F., coating and particle side down to a glass microscope slide using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. The T50 substrate was then removed, leaving the particles arranged on the glass, held by the QPAC 40 layer. 
     Example 6 
     Landless Replication with Adhesive Layer Via Mask Method 
     A coating solution was prepared by dissolving enough of QPAC 40 in 1-3 dioxolane to produce a final weight percent of 5% QPAC 40. The coating solution was delivered at a rate of 30 cm 3 /min to a 10.2 cm (4 inch) wide slot-type coating die. After the solution was coated on the backside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, the coated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m (30 ft) conventional air floatation drier with all 3 zones set at 65.5° C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10 ft/min) to achieve coated film with a wet coating thickness of about 80 micrometers. 
     A 2 mil perforated film was prepared by laser cutting (LaseX, Inc., White Bear Lake, Minn.) 500 micron diameter holes spaced on 2 cm centers into an 0.008 inch polypropylene film. The perforated film was laminated at 230° F., coating side down to a section of the previously coated film using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. 
     The wells in the film were then filled with FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with the edge of a glass microscope slide. The resulting film was then cured under germicidal lamps for five minutes. A second layer of FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the film and doctoring off the excess with a spatula, leaving a thin layer of uncured FILTEK Supreme+ paste on top of the cured layer, imparting adhesion to the sample. 
     The perforated film was peeled off of the substrate, leaving a particle delivery film that contained particles of cured FILTEK Supreme+ paste in the size and position of the holes in the film, with a thin layer of uncured FILTEK Supreme+ paste on the top of the columns. 
     The cooled particle delivery film was laminated at 230° F., coating and particle side down to a glass microscope slide using a thermal film laminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.). The laminated sample was allowed to cool to room temperature. The resulting laminate was then cured under germicidal lamps for five minutes. The T50 liner and QPAC 40 substrate was then removed, leaving the particles arranged on the glass. 
     Example 7 
     Coated Encapsulated Pillars 
     A particle delivery film was created by applying FILTEK Supreme+ paste drop wise to 2 mil unprimed PET and grade 36+ shaped abrasive particles prepared according to the disclosure of U.S. Pat. No. 8,142,531 having a side length of about 0.8 mm and about 0.2 mm thick, and a sidewall angle of 98 degrees. The particles were pressed into the resin. The sample was crosslinked using 4 passes of ultraviolet irradiation (RPC Industries UV Processor QC 120233AN/DR, Plainfield, Ill.) at 50 f pm in air. Any excess resin surrounding the pillars was removed using a razor blade to create planarized pillars. The planarized pillars were released from the PET by flexing it in a tight radius. 
     A light microscope image at 50× of the FILTEK Supreme+ paste planarized slip cast pillar showed that the pillar appeared as a light core with an opaque nanoparticle resin planarizing one surface.

Technology Classification (CPC): 8