Abstract: A method for building microstructures, comprising the steps of forming a photopolymer mask on a substrate, having a mask thickness equal to or larger than a desired height of a microstructure to be formed; forming a latent image on the photopolymer mask by exposure to light; applying an electrical charge to the photopolymer mask; developing the cavities in the mask with a functional liquid toner material whose electrical charge polarity is the same as the charge on the mask; and solidifying the functional liquid toner material into a useful microstructure.

Abstract: A system and method for the manipulation of nanofibers using electrostatic forces. The nanofibers may be provided in a liquid medium, and the nanofibers may be nano-scale (i.e. measured in nanometers). The process is sensitive to the charge properties of the nanofibers (charge could be inherent to material or the charge can be induced into the material through electrochemical means), and therefore may be used to sort or classify particles. The nanofibers may also be aligned according to electrical fields, and thus anisotropic effect exploited. Devices produced may be conductors, semiconductors, active electronic devices, electron emitters, and the like. The nanofibers may be modified after deposition, for example to remove charge-influencing coatings to further enhance their performance, to enhance their adhesion to polymers for use as composite materials or result in the adhesion of the material at the proper location on a variety of different surfaces.

Abstract: Electrostatic printing methods are used to allow the precise placement of small, discrete components on a substrate. The components are configured as liquid toners by coating one or more surfaces with a charge control agent which reacts with a charge director in a diluent to create a charge on the coated components allowing them to be manipulated and placed using electrical fields.

Abstract: A novel process for fabricating low cost RFID devices in which a pattern of metallic toner is printed on a substrate and the contacts on a silicon die are placed directly on contact points printed as part of the pattern of metallic toner; the whole device is then heated to both cure the metallic toner into metallic conductors and bond the silicon die to the metallic conductors. Alternatively, the silicon die can be physically attached to the substrate and the electrical pathway between the silicon die and the metallic conductors is established via a transformer coupling comprised of a coil winding on the silicon die and a pattern of coils printed as part of the metallic toner pattern. The pattern of coils can be comprised of individually printed coil loops printed on, and separated by, dielectric layers.

Abstract: Liquid toners suitable for use in the electrostatic printing of functional materials to produce microstructures such as ribs, electrodes, spacers or filters, and methods of producing the liquid toners. The functional materials, which may include metals, glass and phosphors, are suspended as particles in a dilutent, which may be a non-polar liquid. The surface, or portions of the surface, of the functional material particles are given an appropriate acidic or hydroxyl functionality necessary for their use in electrostatic imaging either by etching or by coating with a material having the appropriate surface functionality.

Abstract: A method for producing a latent image of differentially charged regions on an electrostatic printing plate that may subsequently be realized using toner particles. The printing plate's electrically conducting substrate is coated with a layer of photo-polymer material that has a low electrical conductivity in a normal state. Selected regions of the photo-polymer are then exposed to radiation of a wavelength that produces cross-linking of the photo-polymer. The surface of the photo-polymer is then charged using a corona-discharge while the conducting substrate is grounded. The applied charge is discharged in the unexposed, normal regions of the photo-resist, and retained in the cross-linked regions that were exposed to the radiation because the cross-linking increases the electrical resistance of the photo-polymer. The result is a latent image of differential charge.

Abstract: A method and apparatus for the electrostatic printing of dry or wet toners using a novel tiered printing plate allows for superior and efficient transfer of toner from the plate to the printed item. The process for producing the printing plate uses photo polymer film resist with a positive photo tool which after developing yields trenches between ridges of hardened photo polymer which hold the toner in desired pattern.

Abstract: The invention describes techniques for the electrostatic printing of functional materials configured as liquid toners (45) on glass substrates (26) in a non-contact mode. The toners are patterned by a sensitized electrostatic printing plate (11) of fixed image configuration. Toner images (50) are transferred by an electric field (33) across a fluid filled mechanical gap (42) to the glass substrate (26). Techniques for optimizing the imaging and transfer processes are also disclosed. Two other techniques in which partially finished pieces are manipulated to “self-part” themselves, are described. In both cases defects in the pieces will over print the defect in the “self-healing” mode.

Abstract: The present invention relates to the fabrication of a durable electrostatic printing plate. The electrostatic printing plate includes a substrate with an image receiving layer applied thereto. The image receiving layer includes a permanent pattern defined by an amorphous region and a polycrystalline region.

Abstract: The present invention relates to the fabrication process for the printed wiring boards and flex circuits. An electrostatic printing plate includes a substrate with an image receiving layer applied thereto. The image receiving layer is a toner with a metallic toner and subsequently fixed in place or is transferred to a layer. The metal toner is then fixed on this receiving surface.

Abstract: Particles are applied to the surfaces of materials, especially in the form of discontinuous or patterned coatings on the surfaces of sheet materials by a process comprising the steps of:a) providing a support,b) placing a bed of non-adhered particles on the support, the particles being capable of being moved by an electric field of less than 100 KV/cm,c) placing a mask with a first and second surface over the bed of non-adhered particles, the mask having holes which pass from the first to the second surface, the first surface facing the bed of non-adhered particles without the mask touching the bed of non-adhered particles, the holes in the mask having a size which would allow passage of individual particles from the bed of non-adhered particles through the holes,d) placing a receptor material capable of at least temporarily retaining an electric charge adjacent to the second surface of the mask, which second surface faces away from the bed of non-adhered particles,e) applying an electrical charge to the rece