Abstract: A process for making a microneedle array master comprises: (a) providing a photoreactive composition, the photoreactive composition comprising: (1) at least one reactive species that is capable of undergoing an acid- or radical-initiated chemical reaction, and (2) at least one multiphoton photoinitiator system; and (b) imagewise exposing at least a portion of the composition to light sufficient to cause simultaneous absorption of at least two photons, thereby inducing at least one acid- or radical-initiated chemical reaction where the composition is exposed to the light, the imagewise exposing being carried out in a pattern that is effective to define at least the surface of a plurality of microneedles. The microneedles may be solid and the outer surface of the microneedles may be characterized by at least one concave area. The master may be used to fabricate a tool for replication.

Abstract: The invention features protective film constructions that may be used, for example, as a protective floor finish.

Abstract: Microneedles and microarrays comprising such microneedles are described. The microneedles comprise: a base; a shaft portion extending from the base to a second end distal from the base; a microblade structure extending from the second end; capillary spaces associated with the microblade structure; and a coating in the capillary spaces, the coating comprising an active component. The invention also provides a method for delivering an active component through mammalian skin, comprising: applying the medical device to mammalian skin so that the at least one microneedle is inserted through the stratum corneum and the active component is exposed to interstitial fluids; and allowing the at least one microneedle to remain inserted through the stratum corneum for a sufficient amount of time to dissolve the active component.

Abstract: Methods of forming patterned coatings are disclosed. The methods include the steps of disposing a composition onto a substrate to form a liquid coating on the substrate and removing or providing energy through a first pattern of areas on the liquid coating to form a topographically patterned coating, the topographical pattern corresponding to the first pattern of areas.

Abstract: Methods of forming patterned coatings are disclosed. The methods include the steps of disposing a composition onto a substrate to form a liquid coating on the substrate and providing or removing energy through a first pattern of areas on the coated film to form a morphologically patterned coating, the morphological pattern corresponding to the first pattern of areas.

Abstract: An apparatus comprising a die having at least one application slot. The slot is in fluid communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in pressure within the expansible chamber device. Another aspect of the invention is a method of translating a liquid through a die. A coating die is provided. The die comprises at least one applicator slot in fluid communication with a die cavity. An expansible chamber device is disposed within the cavity. The expansible chamber device is actuated by changes in the fluid pressure within the expansible chamber device. The liquid is translated through the die and delivered from the application slot at intervals corresponding to actuation of the expansible chamber device. Another aspect of the invention is a method for forming a die. An apparatus comprising a die having at least one applicator slot in fluid communication with the die cavity is provided.

Abstract: The disclosure relates to a die assembly. The die assembly includes a die housing having a plurality of inner wall sections defining a die cavity, an inlet passageway passing through the die housing in fluid communication with the die cavity, and an outlet passageway passing through the die housing in fluid communication with the die cavity at a position distal from the inlet passageway. The die assembly also includes an insert removably received in the die cavity. The insert includes a body portion having a plurality of outer wall sections, and at least one flow channel is formed between at least one inner wall section of the die housing and each opposite outer wall section of the body portion of the insert. The die assembly includes a means for providing fluid communication between the external supply of fluent material and each of the at least one flow channel and the outlet passageway.

Abstract: A method of applying a material to a moving substrate is disclosed. The method includes providing a die comprising a die body having a cavity therein, wherein the cavity is in fluid communication with an applicator slot. The die is then oriented such that the applicator slot is positioned so as to dispense the material onto the substrate. The material is introduced into the die cavity such that the material is dispensed onto the substrate through the applicator slot. At least one end of the slot includes means for preventing lateral widening of the dispensed material. In another embodiment, means will be disposed at both ends of the applicator slot. The method is particularly useful when the capillary number characteristic of the coating process is less than 0.

Abstract: Patterned articles can be prepared by applying a release polymer to a substrate in a desired pattern, applying a substrate-adherent polymer over the pattern and substrate, and mechanically removing the substrate-adherent polymer from the pattern without requiring solvent. Suitable mechanical removal methods include applying adhesive tape to the substrate-adherent polymer and peeling the tape and substrate-adherent polymer away from the pattern, and abrading the substrate-adherent polymer from the pattern using impact media.

Abstract: The invention is a die comprising a die body. The die body defines an internal cavity and an applicator slot. The cavity is in fluid communication with the applicator slot. A plurality of gas relief passages are in fluid communication with the internal cavity.

Abstract: Patterned articles can be prepared by applying a release polymer to a substrate in a desired pattern, applying a substrate-adherent polymer over the pattern and substrate, and mechanically removing the substrate-adherent polymer from the pattern without requiring solvent. Suitable mechanical removal methods include applying adhesive tape to the substrate-adherent polymer and peeling the tape and substrate-adherent polymer away from the pattern, and abrading the substrate-adherent polymer from the pattern using impact media.

Abstract: The invention is a die comprising a die body. The die body defines an internal cavity and an applicator slot. The cavity is in fluid communication with the applicator slot. A plurality of gas relief passages are in fluid communication with the internal cavity.

Abstract: An apparatus comprising a die having at least one application slot. The slot is in fluid communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in pressure within the expansible chamber device. Another aspect of the invention is a method of translating a liquid through a die. A coating die is provided. The die comprises at least one applicator slot in fluid communication with a die cavity. An expansible chamber device is disposed within the cavity. The expansible chamber device is actuated by changes in the fluid pressure within the expansible chamber device. The liquid is translated through the die and delivered from the application slot at intervals corresponding to actuation of the expansible chamber device. Another aspect of the invention is a method for forming a die. An apparatus comprising a die having at least one applicator slot in fluid communication with the die cavity is provided.

Abstract: The invention is a die for dispensing flowable material. The die is comprised of a die block. An external face is disposed on the die block. At least one slot extends perpendicularly into the external face. The slot has a longitudinal dimension, a first longitudinal side and a second longitudinal side. At least one support member extends from the external surface into the slot. The support member extends continuously from the first longitudinal side to the second longitudinal side. At least a portion of the support member is disposed in a direction other than perpendicular to the longitudinal dimension. The support member is disposed to such that at least a portion of any plane extending from the first longitudinal side to the second longitudinal side, in a direction perpendicular to the longitudinal dimension of the slot, passes through a void area.

Abstract: Methods of high speed coating a pigment-containing liquid coating material onto a substrate so as to avoid visible pigment separation in the coating material in its as coated state. In the method, a pigment-containing liquid coating material is applied to a substrate, while the substrate is moving at a high line speed of at least about 15.24 m/min., to form a coated layer. The coating material is applied to the substrate along a substantially straight, dynamic wetting line where the coating material first contacts the moving substrate. The coating material is of the type that will exhibit visible pigment separation on its interface surface when the coating material is coated onto the fast moving substrate, without the use of a substantially straight wetting line. The wetting line is substantially straight when a significant amount of visible pigment separation does not occur at the chosen high line speed.

Abstract: Methods of high speed coating a pigment-containing liquid coating material onto a substrate so as to avoid visible pigment separation in the coating material in its as coated state. In the method, a pigment-containing liquid coating material is applied to a substrate, while the substrate is moving at a high line speed of at least about 15.24 m/min., to form a coated layer. The coating material is applied to the substrate along a substantially straight, dynamic wetting line where the coating material first contacts the moving substrate. The coating material is of the type that will exhibit visible pigment separation on its interface surface when the coating material is coated onto the fast moving substrate, without the use of a substantially straight wetting line. The wetting line is substantially straight when a significant amount of visible pigment separation does not occur at the chosen high line speed.