Abstract: A rotary die apparatus and method for determining a registration error of a pattern applied to a strip of material by a rotary die. The rotary die apparatus may comprise the rotary die and a control system which senses signals from a sensor and a rotary encoder to determine an actual position of the rotary die when a fiducial on the strip of material is sensed. The control system may calculate the registration error by comparing the actual position with a registration target corresponding to a pattern length. The pattern length may correspond to the number of encoder pulses output per revolution of the rotary die divided by the number of patterns spaced apart around the circumference of the rotary die. An encoder count used to determine the actual position of the rotary die may reset each time it reaches the pattern length.

Abstract: Systems and methods are described for efficient laser processing of a moving web-based material. In one embodiment, a moving web is provided at a selected speed. A laser beam is generated having a focal point positioned to provide either a score or cut in the web. The focal point of the laser beam is moved at a speed less than the selected speed for a selected distance thereby producing a discreet score or cut in the web in the machine direction. The focal point is repositioned to form another discreet score or cut once the prior discreet score or cut is formed. The repositioned focal point is moved at a speed less than the selected speed for another selected distance. The step of repositioning is repeated to form a plurality of discreet scores or cuts in the web moving at the selected speed. The laser beam is therefore able to be generated using less power than would be needed to produce the same type of discreet score or cut if the focal point were stationary as the web is moved at the selected speed.

Abstract: A method of scoring a multi-layer film structure, wherein the multi-layer film structure comprises a metal layer and polymer layer bonded to each other, the method comprises using a single laser beam incident to the polymer layer to produce a score line in the polymer layer, wherein the laser energy is absorbed only by the metal layer.

Abstract: A laser processing system includes a metal platform having a metal surface wherein at least a portion of the platform surface is substantially planar with a substantially smooth topography. A laser source is configured to generate a laser beam having a focal point that is directed toward a substantially planar portion of the platform surface. A motion mechanism is configured to move at least one of the metal platform and the focal point along at least one axis. A restraining mechanism restrains a film against the platform surface such that an adjoining surface of the restrained film remains in intimate contact with the surface. A controller is configured to operate the laser source, the motion mechanism or both to cut the restrained film in a predetermined pattern with a generated laser beam such that the cut does not extend through the adjoining surface of the restrained film.

Abstract: A method for preventing a plume from contaminating a surface of material that has been cut by a laser or focusing optic wherein the laser produces the plume, the method comprises providing a first airflow beneath the plume with the airflow redirecting the plume away from the surface of the material. A second airflow is provided to further lift the plume to an exhaust. Apparatus is configured to direct first and second air flows such that the plume is not deposited on the material being cut by the laser or on the focusing optic.

Abstract: A method of forming a PV module includes forming conductors on a top surface of a PV coated substrate; forming insulators on the top surface of the PV coated substrate; and cutting the PV coated substrate to form a plurality of individual PV cells. The PV coated substrate is cut so that each of the PV cells has some of the conductors and an insulator on its top surface. Multiple PV cells are then joined to form a PV module by attaching an edge of a first one of the PV cells under an edge of a second one of the PV cells so that at least a portion of the conductors on the first PV cell electrically contacts a bottom surface of the second PV cell.

Abstract: An embossing/debossing system and method for embossing or debossing an impressionable material, such as paper. The system may comprise a laser cutting apparatus and a stamping apparatus. The laser cutting apparatus may comprise a laser configured for cutting and/or ablating one or more patterns into a stencil material. The stamping apparatus may be configured to receive the stencil material from the laser cutting apparatus and may have an actuatable elastomeric press pad configured to press the impressionable material into the patterns formed in the stencil material by the laser cutting apparatus. The system may also comprise various feeding devices configured to feed the stencil material from the laser cutting apparatus to the stamping apparatus and/or configured to feed the impressionable material through the stamping apparatus.

Abstract: A screen printing apparatus and method for applying paste to a substrate while agitating the paste through vibration or pulsating of one or more pulse sources. The screen printing apparatus may comprise a support structure including a frame, a stencil supported by the frame, a squeegee configured to contact the stencil and transfer the paste through apertures of the stencil, and at least one pulse source attached to the support structure and configured to agitate the paste on the stencil. The pulse sources may be configured to attach to and vibrate the frame, squeegee, or other components contacting the paste. Some of the pulse sources may vibrate in different directions relative to each other. In some embodiments of the invention, the pulse source may be configured to be directly inserted or immersed in the paste resting on the stencil during various steps of the printing method.

Abstract: A method of forming a PV module includes forming conductors on a top surface of a PV coated substrate; forming insulators on the top surface of the PV coated substrate; and cutting the PV coated substrate to form a plurality of individual PV cells. The PV coated substrate is cut so that each of the PV cells has some of the conductors and an insulator on its top surface. Multiple PV cells are then joined to form a PV module by attaching an edge of a first one of the PV cells under an edge of a second one of the PV cells so that at least a portion of the conductors on the first PV cell electrically contacts a bottom surface of the second PV cell.

Abstract: A rotary die apparatus and method for determining a registration error of a pattern applied to a strip of material by a rotary die. The rotary die apparatus may comprise the rotary die and a control system which senses signals from a sensor and a rotary encoder to determine an actual position of the rotary die when a fiducial on the strip of material is sensed. The control system may calculate the registration error by comparing the actual position with a registration target corresponding to a pattern length. The pattern length may correspond to the number of encoder pulses output per revolution of the rotary die divided by the number of patterns spaced apart around the circumference of the rotary die. An encoder count used to determine the actual position of the rotary die may reset each time it reaches the pattern length.

Abstract: Systems and methods are described for efficient laser processing of a moving web-based material. In one embodiment, a moving web is provided at a selected speed. A laser beam is generated having a focal point positioned to provide either a score or cut in the web. The focal point of the laser beam is moved at a speed less than the selected speed for a selected distance thereby producing a discreet score or cut in the web in the machine direction. The focal point is repositioned to form another discreet score or cut once the prior discreet score or cut is formed. The repositioned focal point is moved at a speed less than the selected speed for another selected distance. The step of repositioning is repeated to form a plurality of discreet scores or cuts in the web moving at the selected speed. The laser beam is therefore able to be generated using less power than would be needed to produce the same type of discreet score or cut if the focal point were stationary as the web is moved at the selected speed.

Abstract: An apparatus that divides a single laser beam into two or more beams that can be directed at an object, such as a work piece, to perform laser heat treatment is disclosed. An adapter stage is in optical communication with a light source, such as a laser source, and arranged to receive a light beam from the light source. A focus stage in optical communication with the adapter stage is arranged to receive the light beam from the adapter stage and to focus the light beam. A beam splitting stage in optical communication with the focus stage is arranged to receive the focused light beam and to split the focused light beam into a multiple light beams. A redirection stage in optical communication with the beam splitting stage is arranged to receive the multiple light beams and to direct them toward a plurality of target locations on the object.

Abstract: A method and apparatus for monitoring characteristics of a fluid contained in a vessel includes a pair of triangular fluid displacers suspended in the vessel. The buoyant forces acting on the fluid displacers are measured using force transducers and used to calculate fluid characteristics such as the height of the fluid in the vessel, fluid density, solute concentration, and/or the presence of fluid cascading from one section of the vessel to another.

Abstract: A method and system employing a feedback signal indicative of monitored motion of an electro-mechanical acoustic transducer to generate one or both of a control signal for driving the transducer at its natural resonance frequency, and a warning signal indicating that the transducer is not vibrating at a frequency within a selected frequency range. In preferred embodiments, the transducer is a voice coil loudspeaker mounted in or on a vehicle. In other preferred embodiments, the electro-mechanical transducer is driven by an initial electrical pulse followed by a sequence of electrical pulses. A feedback signal indicative of monitored motion of a moving portion of the transducer is generated. Each pulse (following the initial pulse) is applied at a time (determined by the feedback signal) so as to drive the transducer at its actual natural resonance frequency.

Abstract: The present invention provides a vapor processing apparatus in which the vapor is generated in a region adjacent to the vapor processing area. This is generally done in a batch process and a limited volume of processing vapor is generated for each batch. The separation of the vapor generation from the processing avoids the contamination of the vapor source and the inadvertent cooling of the vapor generating area. In the preferred embodiment, two vessels are disposed one inside the other such that a vapor generating region is provided in the annular space between vessels. The vapor is injected into the processing region through channels formed in the annular space. In a preferred embodiment, the vapor is isopropyl alcohol and the substrates for processing are silicon wafers.

Abstract: The present suspension mechanism for load dividing gates of single column type promotes reliability and safety by extreme simplicity and unity of carriage structure, together with highly effective provision against structural failure even of the inherently rugged support elements. By means of features including special bearing design, roller placement and novel keeper support, the invention provides suspension of a column gate from a single track with security against structural failure believed at least equal to that normally attained for conventional gates with dual track support. Improved manual control mechanism for the locking pins provides in highly compact and reliable form independent operation either from inside the car or from outside through an open doorway.

Abstract: A high resolution, high speed laser drilling system for operating on an advancing product operates to advances the product in a predetermined product advancement path at a product advancement speed. A laser-generating source provides a pulsed laser beam having a laser-on time and a laser-off time. The laser beam is reflected to direct a focal point of the laser beam onto the advancing product. The focal point of the laser beam is moved in a direction of the product advancement path during the laser-on time and is moved in a direction opposite to the direction of the product advancement path during the laser-off time. The system is therefore able to improve laser drilling resolution for a given product advancement speed.