Abstract: A retroreflective sign comprising a rigid substrate with a pattern of cell walls formed of a polyurethane adhesive or two-part polyurea adhesive, and a polymeric sheet having a front face and a rear face, the rear face facing the substrate, the rear face comprising microprismatic reflective elements is disclosed. The polymeric sheet is adhered directly to the cell walls formed of the polyurethane adhesive or two-part polyurea adhesive while leaving an air gap between the microprismatic retroreflective elements and the rigid substrate in the cells. A method of making the retroreflective sign includes applying a polyurethane adhesive or two-part polyurea adhesive to a front side of a rigid substrate in a pattern defining cell walls; and prior to full curing of the polyurethane adhesive, laminating the front side of the rigid substrate a rear side of a polymeric sheet via the cell walls, the polymeric sheet comprising microprismatic elements.

Abstract: A retroreflective sign comprising a rigid substrate with a pattern of cell walls formed of a polyurethane adhesive or two-part polyurea adhesive, and a polymeric sheet having a front face and a rear face, the rear face facing the substrate, the rear face comprising microprismatic reflective elements is disclosed. The polymeric sheet is adhered directly to the cell walls formed of the polyurethane adhesive or two-part polyurea adhesive while leaving an air gap between the microprismatic retroreflective elements and the rigid substrate in the cells. A method of making the retroreflective sign includes applying a polyurethane adhesive or two-part polyurea adhesive to a front side of a rigid substrate in a pattern defining cell walls; and prior to full curing of the polyurethane adhesive, laminating the front side of the rigid substrate a rear side of a polymeric sheet via the cell walls, the polymeric sheet comprising microprismatic elements.

Abstract: A method for forming a microneedle array, wherein the microneedle array includes a base surface and an elongated body portion terminating in a sharp tip, and is attached to a polymeric backing layer, includes the steps of: charging a first liquid comprising sugar and an active drug to a microneedle mold; drying the first liquid; optionally charging a second liquid comprising sugar to the microneedle mold and drying the second liquid; adhering a polymeric backing layer to the base surface of the microneedles formed in the microneedle mold to form the microneedle array. A powder coating method, and apparatus for conducting the methods and producing the product are included also.

Abstract: A retroreflective sign comprising a rigid substrate with a pattern of cell walls formed of a polyurethane adhesive or two-part polyurea adhesive, and a polymeric sheet having a front face and a rear face, the rear face facing the substrate, the rear face comprising microprismatic reflective elements is disclosed. The polymeric sheet is adhered directly to the cell walls formed of the polyurethane adhesive or two-part polyurea adhesive while leaving an air gap between the microprismatic retroreflective elements and the rigid substrate in the cells. A method of making the retroreflective sign includes applying a polyurethane adhesive or two-part polyurea adhesive to a front side of a rigid substrate in a pattern defining cell walls; and prior to full curing of the polyurethane adhesive, laminating the front side of the rigid substrate a rear side of a polymeric sheet via the cell walls, the polymeric sheet comprising microprismatic elements.

Abstract: A retroreflective sign comprising a rigid substrate with a pattern of cell walls formed of a polyurethane adhesive or two-part polyurea adhesive, and a polymeric sheet having a front face and a rear face, the rear face facing the substrate, the rear face comprising microprismatic reflective elements is disclosed. The polymeric sheet is adhered directly to the cell walls formed of the polyurethane adhesive or two-part polyurea adhesive while leaving an air gap between the microprismatic retroreflective elements and the rigid substrate in the cells. A method of making the retroreflective sign includes applying a polyurethane adhesive or two-part polyurea adhesive to a front side of a rigid substrate in a pattern defining cell walls; and prior to full curing of the polyurethane adhesive, laminating the front side of the rigid substrate a rear side of a polymeric sheet via the cell walls, the polymeric sheet comprising microprismatic elements.

Abstract: A method, apparatus for making, and a retroreflective traffic sign consists of a polymeric film having a front face and a rear face, wherein the rear face has a pattern of microprismatic retroreflective elements integrally formed as part of said film; a pattern of cell walls formed of an adhesive-containing polymer defining cells in which the microprismatic retroreflective elements are in the cells; and a substrate is adhered directly to the cell walls formed of the adhesive-containing polymer while leaving an air gap between the microprismatic retroreflective elements and the substrate in the cells.

Abstract: A continuous polymer sheet casting apparatus includes first and second endless belts positioned in face to face relationship to each other for a portion of their lengths to form between their inside surfaces a mold cavity for molding a polymeric sheet therebetween, and a container in fluid communication with the mold cavity, the container configured to introduce a liquid monomer or liquid polymer and curing agent and/or initiator to the cavity for polymerization therein; a controlled cooling apparatus in thermal communication with the mold cavity, configured to cool and solidify the polymeric sheet as it moves through the mold cavity, wherein either the first, the second, or the first and second endless belts include a microstructured optical quality tool area on at least a portion of said belt or belts. A mold and process for molding is also disclosed.

Abstract: In an embodiment, a molding apparatus for a turbine blade includes first and second mold compartments defining a mold cavity when in a closed position, at least one of the first and second mold compartments including a micro-structured surface facing an interior of the mold cavity. The micro-structured surface includes an array of V-shaped channels, and the V-shaped channels have a maximum height of 200 micrometers. A turbine blade including integral micro-structured riblets and method for making the turbine blade is also provided.

Abstract: A method is provided for forming at least one curved polymeric microneedle, wherein the microneedle includes a base portion and an elongated body portion terminating in a sharp tip, said elongated body portion comprising a lower portion that is 15% to 25% of the height of the microneedle, said elongated body portion being connected to said base layer. The method comprises: heating an array comprising said base layer and at least a segment of said elongated body portion; passing the heated array against a fixed member to bend the microneedles; and allowing the bent, heated array to be cooled. The heat applied to the base layer and elongated body portion is sufficient to cause the heated microneedle to be at or above the glass transition temperature of the polymer of the microneedle, but below a temperature that would cause the lower portion to bend during the passing step.

Abstract: In an embodiment, a molding apparatus for a turbine blade includes first and second mold compartments defining a mold cavity when in a closed position, at least one of the first and second mold compartments including a micro-structured surface facing an interior of the mold cavity. The micro-structured surface includes an array of V-shaped channels, and the V-shaped channels have a maximum height of 200 micrometers. A turbine blade including integral micro-structured riblets and method for making the turbine blade is also provided.

Abstract: A method, apparatus for making, and a retroreflective traffic sign consists of a polymeric film having a front face and a rear face, wherein the rear face has a pattern of microprismatic retroreflective elements integrally formed as part of said film; a pattern of cell walls formed of an adhesive-containing polymer defining cells in which the microprismatic retroreflective elements are in the cells; and a substrate is adhered directly to the cell walls formed of the adhesive-containing polymer while leaving an air gap between the microprismatic retroreflective elements and the substrate in the cells.

Abstract: A method, apparatus for making, and a retroreflective traffic sign consists of a polymeric film having a front face and a rear face, wherein the rear face has a pattern of microprismatic retroreflective elements integrally formed as part of said film; a pattern of cell walls formed of an adhesive-containing polymer defining cells in which the microprismatic retroreflective elements are in the cells; and a substrate is adhered directly to the cell walls formed of the adhesive-containing polymer while leaving an air gap between the microprismatic retroreflective elements and the substrate in the cells.

Abstract: A method, apparatus for making, and a retroreflective traffic sign consists of a polymeric film having a front face and a rear face, wherein the rear face has a pattern of microprismatic retroreflective elements integrally formed as part of said film; a pattern of cell walls formed of an adhesive-containing polymer defining cells in which the microprismatic retroreflective elements are in the cells; and a substrate is adhered directly to the cell walls formed of the adhesive-containing polymer while leaving an air gap between the microprismatic retroreflective elements and the substrate in the cells.

Abstract: A novel array of hollow silica glass microneedles is provided. The array is prepared from a silica dispersion. A novel apparatus is provided comprising a negative mold component having tapered openings therein and a positive mold component having positive elements that are received within the tapered openings of the negative mold component. An assembly is prepared of the negative mold component and the positive mold component, with an aqueous silica dispersion received within the space between the outer surface of the positive elements and the inner surface of the openings. The assembly is heated to remove air and water vapors from the silica dispersion, then the assembly is further heated to sinter the remaining silica to silica glass. The sintered silica glass when removed from the mold components is in the form of an array of microneedles.

Abstract: A roller type window shade for directing daylight onto the ceiling of an associated room in which the shade is positioned on a window of such room, the shade comprising a polymer film having a width commensurate with the width of the associated window and length commensurate with the length of the associated window, said film having at least one microprismatic area integrally formed as part of said film and extending along the width of said shade for redirecting daylight upwardly toward the ceiling of the associated room, and whereby the position of the shade can increase or decrease both the daylight directing and image visible area of the associated window.

Abstract: A roller type window shade for directing daylight onto the ceiling of an associated room in which the shade is positioned on a window of such room, the shade comprising a polymer film having a width commensurate with the width of the associated window and length commensurate with the length of the associated window, said film having at least one microprismatic area integrally formed as part of said film and extending along the width of said shade for redirecting daylight upwardly toward the ceiling of the associated room, and whereby the position of the shade can increase or decrease both the daylight directing and image visible area of the associated window.

Abstract: A process and apparatus for embossing relatively rigid polymeric panels having precise microstructured surfaces on at least one face of the panel including using a continuous press having upper and lower belts; providing tools with the embossing pattern(s); feeding the tools and panels juxtaposed thereon through the press where heat and pressure are applied to form the em bossed precise microstructured surface and cooling the embossed panel, all while maintaining pressure on the panel and the tool, and thereafter separating the embossed polymeric panel from the tool.

Abstract: A novel array of hollow silica glass microneedles is provided. The array is prepared from a silica dispersion. A novel apparatus is provided comprising a negative mold component having tapered openings therein and a positive mold component having positive elements that are received within the tapered openings of the negative mold component. An assembly is prepared of the negative mold component and the positive mold component, with an aqueous silica dispersion received within the space between the outer surface of the positive elements and the inner surface of the openings. The assembly is heated to remove air and water vapors from the silica dispersion, then the assembly is further heated to sinter the remaining silica to silica glass. The sintered silica glass when removed from the mold components is in the form of an array of microneedles.

Abstract: The apparatus comprises a mold assembly including at least one bore therethrough having a cavity therein defining the shape of the finished microneedle shape to be formed therein. The bore has an inlet opening and an exit opening. The apparatus also comprises means for locating the polymer to be formed at one end of the cavity and means for introducing fluid into the inlet opening of said bore and into the cavity. The apparatus also comprises exhaust means communicating with the exit opening of the bore, so that introducing the fluid through the polymer causes the polymer to assume the shape of the cavity and the fluid forms a hollow channel to define a needle-like structure in the polymer as the fluid is exhausted through the cavity and the bore.

Abstract: There is disclosed a method and apparatus for producing a polymeric film that accurately replicates a complex mold surface at least a portion of which surface has microstructured or nano-structured dimensions. A polymeric powder is electrodeposited on an underlying mold surface. Then the powder is cured to create a polymeric film. Finally the film is removed from the mold surface.