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International Polymer Processing, Vol.22, No.4, 375-379, 2007
Constant temperature microfeature embossing with slowly crystallizing polymers
A new microfeature embossing method utilizing a slowly crystallizing mechanism was investigated to eliminate thermal cycling, as needed in standard hot embossing. Poly(ethylene terephthalate) was used as a model system for demonstration. Due to its slow crystallization, amorphous PET film can be made by melt casting onto a chilled roll. The resulting amorphous film was embossed at a constant temperature of 180 degrees C for a period of time comparable to or longer than the polymer's half-time of crystallization. During constant-temperature embossing, the film is softened first, caused by rubber softening of the amorphous phase, and is then hardened, resulting from the crystallization of the amorphous phase at the same embossing temperature. Since the embossed film is hardened under the constant mold temperature, no cooling is needed. Selected micro features, including circular microchannels and high aspect ratio microribs, were consistently patterned using a total cycle time about 40 s. The embossed films were characterized using DSC and rotational rheometry to elucidate the physical mechanism for softening and hardening the polymer during constant-temperature embossing.