Abstract: Methods of electroforming fuel injector nozzle structures such as, e.g., nozzle plates, valve guides, combinations of nozzle plates and valve guides, etc., as well as other articles incorporating microstructured features. The methods described herein can be used to electroform articles with high aspect ratio features in close proximity while reducing the likelihood of void formation during the electroforming process.

Abstract: Methods of manufacturing fuel injector nozzle structures such as, e.g., nozzle plates, valve guides, combinations of nozzle plates and valve guides, etc., as well as other articles incorporating microstructured features. The methods may employ multiphoton processes to form microstructured patterns on a three-dimensional structured surface to provide nozzle structures and other articles that include finished microstructured features such as, e.g., through-holes extending from one or more cavities, where at least a portion of the three-dimensional structured surface is used to form the cavities. Forming a microstructured pattern on a three-dimensional structured surface can reduce the time needed to form nozzle structures that include microstructured features and other nozzle structure features (e.g., cavities) by avoiding the need to form the other nozzle structure features using the multiphoton processes.

Abstract: The present disclosure relates to pillars useful in the fabrication of insulated glass units, particularly, vacuum glazing, insulated glass units. The invention also relates to insulated glass units containing said pillars. The present disclosure provides a pillar for use in a vacuum insulated glass unit wherein the pillar includes a body. The body includes a plurality of first structures, at least one first void region between the plurality of first structures; and a first land surface region located between the plurality of first structures and at least one first channel having first and second ends and a first channel opening proximate the first surface of the body. The first channel is in fluid communication with the local environment through at least one of its first and second ends, and the at least one first void region is in fluid communication with at least one of the local environment in a direction parallel to the first surface and the at least one first channel.

Abstract: A method of fabricating a structure includes disposing a liquid photoreactive composition on a substrate, exposing a portion of the liquid photoreactive composition to laser light of sufficient intensity and wavelength to cause polymerization via two-photon excitation of the two-photon sensitizer and polymerization of a portion of the liquid photoreactive composition thereby providing an exposed composition; and developing the exposed composition to provide the structure. The liquid composition includes: at least one cationically polymerizable polyepoxide; at least one compound comprising free-radically polymerizable groups; an effective amount of a two-photon photoinitiator system, wherein the weight ratio of component (a) to component (b) is from 25:75 to 75:25, inclusive. The two-photon photoinitiator system includes a two-photon sensitizer and an aromatic onium salt. The liquid photoreactive composition may contain less than about one percent by weight of organic solvent.

Abstract: The present disclosure relates to pillars useful in the fabrication of insulated glass units, particularly, vacuum glazing, insulated glass units. The invention also relates to insulated glass units containing said pillars. The present disclosure provides a pillar for use in a vacuum insulated glass unit wherein the pillar includes a body. The body includes a plurality of first structures, at least one first void region between the plurality of first structures; and a first land surface region located between the plurality of first structures and at least one first channel having first and second ends and a first channel opening proximate the first surface of the body. The first channel is in fluid communication with the local environment through at least one of its first and second ends, and the at least one first void region is in fluid communication with at least one of the local environment in a direction parallel to the first surface and the at least one first channel.

Abstract: The present disclosure relates to pillars useful in the fabrication of insulated glass units, particularly, vacuum glazing, insulated glass units. The invention also relates to insulated glass units containing said pillars. The present disclosure provides a pillar for use in a vacuum insulated glass unit wherein the pillar includes a body. The body includes a first surface and an opposed second surface, at least one sidewall, and a first peripheral edge adjoining the first surface and the at least one sidewall. In some embodiments, at least a portion of the first peripheral edge may be a chamfered peripheral edge. In other embodiments, at least a portion of the first peripheral edge is rounded peripheral edge. The largest dimension of the body parallel to the first surface is between about 10 microns and about 2000 microns. The body may include a continuous, inorganic material.

Abstract: A method of fabricating a structure includes disposing a liquid photoreactive composition on a substrate, exposing a portion of the liquid photoreactive composition to laser light of sufficient intensity and wavelength to cause polymerization via two-photon excitation of the two-photon sensitizer and polymerization of a portion of the liquid photoreactive composition thereby providing an exposed composition; and developing the exposed composition to provide the structure. The liquid composition includes: at least one cationically polymerizable polyepoxide; at least one compound comprising free-radically polymerizable groups; an effective amount of a two-photon photoinitiator system, wherein the weight ratio of component (a) to component (b) is from 25:75 to 75:25, inclusive. The two-photon photoinitiator system includes a two-photon sensitizer and an aromatic onium salt. The liquid photoreactive composition may contain less than about one percent by weight of organic solvent.

Abstract: A system for making flexible circuit films includes an inelastic conveyor, a web handling apparatus configured to pass a flexible substrate around the inelastic conveyor, an image acquisition apparatus configured to measure positions of a first set of alignment marks on the flexible substrate at a first conveyor location, an exposure apparatus configured to patternwise expose a photosensitive material on the flexible substrate at a second conveyor location, and an image processor configured to receive the measured positions of the first set of alignment marks, and to compare the measured positions with reference positions of the first set of alignment marks. The exposure apparatus is configured to patternwise expose the photosensitive material based on the comparison between the measured positions and the reference positions.

Abstract: Methods and systems for determining longitudinal position of an elongated web are described. Sensors are used to detect one or more substantially continuous fiducial marks disposed longitudinally on the web. The sensors generate signals associated with the fiducial marks. A position detector receives the signals and determines a longitudinal position of the web using the sensor signals. The fiducial marks may be periodic fiducial marks, such as sine and/or cosine marks on the web and/or may be piecewise continuous marks. The coarse longitudinal position of the web can be determined based on periodically recurring features of the fiducial marks. The fine longitudinal position can be determined based on continuous portions of the fiducial marks between the periodically recurring features.

Abstract: Approaches for enhancing web position determination involve phase locking a web movement encoder signal to a sensed web fiducial signal. Fiducials disposed along a longitudinal axis of a substrate are sensed and corresponding sensor signals are generated. An estimated web position is provided by one or more encoder signals. The phase difference between the sensor signals and the encoder signals is calculated and the web position error is determined based on the phase difference. The web position error signal can be fed back to adjust the encoder signals which improves the accuracy of the web position determination.

Abstract: A surface plasmon resonance sensor element includes a thin metallic layer, an optical construction disposed on the thin metallic layer for directing light to and away from the thin metallic layer, and an absorptive layer disposed on the thin metallic layer opposite the optical construction. The absorptive layer includes a polymer of intrinsic microporosity having an average pore volume of at least 0.4 cubic nanometers.

Abstract: Fiducials having substantially continuous portions made on a substrate allow the position of the substrate to be determined. An approach for making fiducials involves moving first and second fiducial devices together back and forth across the substrate along a trajectory having a component along the lateral axis of the substrate while the substrate and the first and second fiducial devices are in relative motion along the longitudinal axis of the substrate. The first fiducial device operates to make one fiducial on the substrate during the movement along the trajectory and the relative motion. The second fiducial device operates to make another fiducial on the substrate during the movement along the trajectory and the relative motion. The fiducials may be formed so that they have a constant spatial frequency with the first fiducial being out of phase with respect to the second fiducial.

Abstract: Approaches for enhancing web position determination involve phase locking a web movement encoder signal to a sensed web fiducial signal. Fiducials disposed along a longitudinal axis of a substrate are sensed and corresponding sensor signals are generated. An estimated web position is provided by one or more encoder signals. The phase difference between the sensor signals and the encoder signals is calculated and the web position error is determined based on the phase difference. The web position error signal can be fed back to adjust the encoder signals which improves the accuracy of the web position determination.

Abstract: Approaches for enhancing web position determination involve phase locking a web movement encoder signal to a sensed web fiducial signal. Fiducials disposed along a longitudinal axis of a substrate are sensed and corresponding sensor signals are generated. An estimated web position is provided by one or more encoder signals. The phase difference between the sensor signals and the encoder signals is calculated and the web position error is determined based on the phase difference. The web position error signal can be fed back to adjust the encoder signals which improves the accuracy of the web position determination.

Abstract: A method of applying a conductive pattern of metal onto a web of indefinite length material. This method includes applying a metal containing composition onto the web in a predefined pattern, providing a roll having a very low thermal mass, and conveying the patterned web around the roll while simultaneously applying heat energy to the metal containing composition thereby converting the metal to a conductive pattern. This allows for flexible circuitry to be fabricated in an inexpensive roll-to-roll process.

Abstract: A surface plasmon resonance sensor element includes a thin metallic layer, an optical construction disposed on the thin metallic layer for directing light to and away from the thin metallic layer, and an absorptive layer disposed on the thin metallic layer opposite the optical construction. The absorptive layer includes a polymer of intrinsic microporosity having an average pore volume of at least 0.4 cubic nanometers.

Abstract: A system for making flexible circuit films includes an inelastic conveyor, a web handling apparatus configured to pass a flexible substrate around the inelastic conveyor, an image acquisition apparatus configured to measure positions of a first set of alignment marks on the flexible substrate at a first conveyor location, an exposure apparatus configured to patternwise expose a photosensitive material on the flexible substrate at a second conveyor location, and an image processor configured to receive the measured positions of the first set of alignment marks, and to compare the measured positions with reference positions of the first set of alignment marks. The exposure apparatus is configured to patternwise expose the photosensitive material based on the comparison between the measured positions and the reference positions.

Abstract: An article having a first major surface with at least first and second regions, the first region comprising a plurality of first structures having a first surface roughness, the second region comprising a plurality of second structures having a second surface roughness, wherein at least a portion of the at least first and second regions have a surface roughness difference between them that together exhibit at least a portion of a first image. Exemplary uses of the articles include tool-less macro-patterning of transflectors, customized appearance for retroreflective sheeting, incorporation of security features, decorative patterns for lighting diffusers, images or logos in medical films without inks or contamination.

Abstract: Methods of making flexible circuit films include providing a polymer film or other flexible substrate having a plurality of alignment marks and a photosensitive material thereon. The substrate passes around a suitable roller, belt, or other inelastic conveyor such that the substrate and the conveyor move together at least from a first location to a second location. Positions of a first set of the alignment marks on a first portion of the substrate are measured when such portion is at the first location, and the measured positions can be used to calculate a distortion of the substrate. The photosensitive material is then patternwise exposed when the first portion of the substrate has moved to the second location. The patternwise exposing is based on the measured positions of the first set of alignment marks, and may include exposing the web with a distortion-adjusted pattern. Related systems and articles are also disclosed.

Abstract: A multifunctional optical film for enhancing light extraction includes a flexible substrate, a structured layer having nanoparticles of different sizes, and a backfill layer. The structured layer effectively uses microreplicated diffractive or scattering nanostructures located near enough to the light generation region to enable extraction of an evanescent wave from an organic light emitting diode (OLED) device. The backfill layer has a material having an index of refraction different from the index of refraction of the structured layer. The backfill layer also provides a planarizing layer over the structured layer in order to conform the light extraction film to a layer of an OLED display device. The film may have additional layers added to or incorporated within it to an emissive surface in order to effect additional functionalities beyond improvement of light extraction efficiency.