US5418007A
Expired / Lapsed
US
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Method for making composite article comprising oriented microstructures
Assignee: 3M Co
•
Filing: 1994-08-01
•
Granted: 1995-05-23
•
Expires: 2014-08-01
Abstract
Abstract This invention provides a composite article having discrete microstructures partially encapsulated within a layer. A method of making the same is also provided. The article of the present invention is useful for visible radiation absorbing devices, such as, for example, selective solar absorbers, flat plate solar collectors, solar absorption panels, and solar cells.
Inventors
- 👤 Mark K. Debe
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 06:21
CPC Classifications
C; C23; C23C; C23C14/00; C23C14/58; C23C14/5806; C23C14/06; C23C14/12; C23C14/14; C23C14/20; C23C14/205; C23C14/584; F; F24; F24S; F24S70/00; F24S70/20; F24S70/225; F24S70/60; H; H10; H10F; H10F77/00; H10F77/10; H10F77/16; H10F77/162; H10F77/70; Y; Y02; Y02E; Y02E10/00; Y02E10/40; Y02E10/44; Y02E10/50; Y10; Y10T; Y10T428/00; Y10T428/25; Y10T428/254; Y10T428/29; Y10T428/2913; Y10T428/2933; Y10T428/2938; Y10T428/31
Claims Analysis
Total Claims: 36
Claim 1
Independent Claim
142 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, wherein said microstructures are selected from the group consisting of organic microstructures, and inorganic semiconductor microstructures, and wherein said microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 2
Independent Claim
142 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, wherein said microstructures are selected from the group consisting of organic microstructures, and inorganic semiconductor microstructures, and wherein said microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 3
Dependent Claim
25 words
The method according to claim 1 wherein said exposed distal ends of said microstructures and said surface of said layer are on a common plane.
Claim 4
Dependent Claim
105 words
The method according to claim 1, wherein said substrate bearing an encapsulated microstructured-layer is provided by the steps of: i) depositing a sufficient amount of an organic material as a layer onto a substrate to provide a deposited organic layer such that after step (ii) a microstructured-layer comprising a dense array of discrete microstructures is formed; ii) annealing said deposited organic layer in a vacuum for a time and at a temperature sufficient to induce a physical change in said deposited organic layer to form a microstructured-layer comprising a dense array of discrete microstructures; and iii) encapsulating said microstructured-layer with at least one encapsulating material.
Claim 5
Dependent Claim
28 words
The method according to claim 3 wherein said layer is deposited by a technique selected from the group consisting of vapor phase deposition, dispersion coating, and solution coating.
Claim 6
Dependent Claim
26 words
The method according to claim 3 further comprising the step of conformal coating said microstructured-layer with at least one coating material prior to encapsulation step iii.
Claim 7
Dependent Claim
29 words
The method according to claim 5 wherein said conformal coating is deposited by a technique selected from the group consisting of vapor phase coating, dispersion coating, and solution coating.
Claim 8
Dependent Claim
13 words
The method according to claim 3 wherein step (i) includes heating said substrate.
Claim 9
Dependent Claim
34 words
The method according to claim 1 wherein said encapsulating material is coated over said microstructured-layer by a technique selected from the group consisting of vapor phase deposition, solution coating, dispersion coating, and solid-liquid deposition.
Claim 10
Dependent Claim
22 words
The method according to claim 5 wherein said conformal coating comprises at least one of an organic material or an inorganic material.
Claim 11
Dependent Claim
37 words
The method according to claim 9 wherein said inorganic material of said conformal coating is selected from the group consisting of metal oxides, metal sulfides, metal chlorides, metal carbides, metal borides, metal nitrides, metal silicides, and metals.
Claim 12
Dependent Claim
18 words
The method according to claim 9 wherein said organic material of said conformal coating is a polymeric material.
Claim 13
Dependent Claim
29 words
The method article according to claim 1 wherein said microstructures have an areal number density in the range from about 1 to about 10 4 microstructures per square micrometer.
Claim 14
Dependent Claim
51 words
The method according to claim 1 wherein said inorganic semiconductor microstructures comprise a material selected from the group consisting of diamond, germanium, selenium, arsenic, silicon, tellurium, gallium arsenide, gallium antimonide, gallium phosphide, aluminum antimonide, indium antimonide, indium tin oxide, zinc antimonide, indium phosphide, aluminum gallium arsenide, zinc teluride, and combinations thereof.
Claim 15
Dependent Claim
27 words
The method according to claim 5 wherein said conformal coating is deposited by a technique selected from the group consisting of vapor phase deposition and solution coating.
Claim 16
Dependent Claim
14 words
The method according to claim 1 wherein each of said microstructures comprises polycrystalline regions.
Claim 17
Dependent Claim
30 words
The method according to claim 1 wherein said organic microstructures comprise organic material, wherein said organic material has planar molecules comprising chains or rings over which II-electron density is delocalized.
Claim 18
Dependent Claim
21 words
The method according to claim 16 wherein said organic material is selected from the group consisting of perylenes, phthalocyanines, and porphyrins.
Claim 19
Dependent Claim
24 words
The method according to claim 1 wherein said encapsulating material is selected from the group consisting of an organic material and an inorganic material.
Claim 20
Dependent Claim
16 words
The method according to claim 1 wherein said microstructures are essentially uniform in size and shape.
Claim 21
Dependent Claim
21 words
The method according to claim 1 wherein said microstructures have an aspect ratio which ranges from about 3:1 to about 100:1.
Claim 22
Independent Claim
129 words
A method for making a composite article comprising a layer having a dense array of discrete ceramic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said ceramic microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete ceramic microstructures directly on said surface of said substrate, wherein said ceramic microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 23
Independent Claim
129 words
A method for making a composite article comprising a layer having a dense array of discrete ceramic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said ceramic microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete ceramic microstructures directly on said surface of said substrate, wherein said ceramic microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 24
Independent Claim
114 words
A method for making a composite article comprising a layer having a dense array of discrete, regularly arrayed, organic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete, regularly arrayed, organic microstructures directly on said surface of said substrate; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 25
Independent Claim
114 words
A method for making a composite article comprising a layer having a dense array of discrete, regularly arrayed, organic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete, regularly arrayed, organic microstructures directly on said surface of said substrate; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 26
Dependent Claim
17 words
The method according to claim 22 wherein said organic microstructures are essentially uniform in size and shape.
Claim 27
Dependent Claim
23 words
The method according to claim 23 wherein said organic microstructures have an aspect ratio in the range from about 3:1 to about 100:1.
Claim 28
Dependent Claim
24 words
The method according to claim 24 wherein said organic microstructures have a mean diameter in the range from about 1 to about 5000 nanometers.
Claim 29
Independent Claim
149 words
A method for making a composite article comprising a layer having a dense array of discrete organic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, wherein interposed between said organic microstructures and said encapsulant is a conformal coating of an inorganic conformal coating material, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said encapsulated microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, an encapsulant, and a conformal coating of an inorganic conformal coating material interposed between said microstructures and said encapsulant; and (b) delaminating said encapsulated microstructured layer from said substrate to provide said composite article.
Claim 30
Independent Claim
149 words
A method for making a composite article comprising a layer having a dense array of discrete organic microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, wherein interposed between said organic microstructures and said encapsulant is a conformal coating of an inorganic conformal coating material, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said encapsulated microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, an encapsulant, and a conformal coating of an inorganic conformal coating material interposed between said microstructures and said encapsulant; and (b) delaminating said encapsulated microstructured layer from said substrate to provide said composite article.
Claim 31
Independent Claim
126 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, and wherein said microstructures have a mean diameter in the range from about 1 to about 1000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 32
Independent Claim
126 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, and wherein said microstructures have a mean diameter in the range from about 1 to about 1000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 33
Independent Claim
128 words
A method for making a composite article comprising a layer having a dense array of discrete metal microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete metal microstructures directly on said surface of said substrate, and wherein said microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 34
Independent Claim
128 words
A method for making a composite article comprising a layer having a dense array of discrete metal microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete metal microstructures directly on said surface of said substrate, and wherein said microstructures have a mean diameter in the range from about 1 to about 5000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 35
Independent Claim
156 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a composite article comprising a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, wherein said microstructures are essentially uniform in size and shape, wherein said microstructures have an aspect ratio in the range from about 3:1 to about 100:1, and wherein said microstructures have a mean diameter in the range from about 1 to about 1000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
Claim 36
Independent Claim
156 words
A method for making a composite article comprising a layer having a dense array of discrete microstructures partially encapsulated therein by an encapsulant, wherein one distal end of each of said microstructures is exposed, and wherein said exposed distal ends of said microstructures and a surface of said layer are on a common side of said layer, said method comprising the steps of: (a) providing a composite article comprising a substrate bearing an encapsulated microstructured-layer, wherein said substrate has a surface, wherein said microstructured-layer comprises a dense array of discrete microstructures directly on said surface of said substrate, wherein said microstructures are essentially uniform in size and shape, wherein said microstructures have an aspect ratio in the range from about 3:1 to about 100:1, and wherein said microstructures have a mean diameter in the range from about 1 to about 1000 nanometers; and (b) delaminating said encapsulated microstructured-layer from said substrate to provide said composite article.
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