Patent ID: 8172564

Claim:
Apparatus for continuously producing a web of film having a complex pattern of microstructured or nanostructured elements in at least a portion thereof, comprising: (a) a mold having a first pattern of microstructured or nanostructured elements in a surface thereon; (b) means for moving said mold along a continuous path; (c) means disposed at at least one location along said path for depositing a first layer of polymeric thermoset or thermoplastic powder resin having a particle size smaller than said microstructured or nanostructured elements onto said moving mold surface; (d) means disposed at at least one location along said path for melting said deposited polymeric powder; (e) optionally, means disposed at at least one location along said path for effecting a cure of said melted deposited polymeric powder whereby said melted and optionally cured polymeric powder will form a film having the desired microstructured or nanostructured pattern thereon; and (f) means for receiving said film having a microstructured or nanostructured surface on at least one side thereof from said moving surface of said mold; wherein said apparatus is operable such that said deposited powder does not completely fill the microstructured pattern on said mold surface, said apparatus further comprising means disposed along said path after said melting means for pressing a polymer sheet onto said deposited polymer to press said deposited polymer into said pattern to a level less than the full depth of said microstructures, whereby when said deposited polymer forms a film and said polymer sheet is removed from said film, said film will have vias formed therethrough.