Abstract: A method of fabricating organic electronic devices is provided. More specifically, methods of fabricating organic electroluminescent devices having active polymer layers are disclosed. The active polymer layers are disposed by a web coating method such as Micro Gravure™ coating. The active polymer layers are patterned using a solvent assisted wiping process.

Abstract: In one embodiment, the method for making the electroform comprises: attaching a sub-master to a first side of a stiffener plate to form a mounted sub-master, masking sides and a second side of the stiffener plate with polyester tape, passivating the surface to form a passivation layer, plating the surface with a metal to form a metal layer, and removing the metal layer to form the electroform.

Abstract: In one embodiment, the method for making a product comprises: contacting a surface of the electroform with a solution having a pH of less than or equal to 6, applying a cathodic current to the electroform, applying a product material to the electroform, curing the product material, and removing the cured material from the electroform to form the product.

Abstract: In one embodiment, the method for making an electroform comprises: passivating a sub-master to form a passivation layer, disposing the passivated sub-master into an initial electroplating solution, applying a first current, depositing a first metal onto the passivated sub-master to form an initial coating on the sub-master, moving the initially coated sub-master from the initial electroplating solution to a subsequent plating solution, applying a second current, depositing a subsequent layer of a second metal onto the initial coating to form a multilayer, and removing the multilayer to form the electroform.

Abstract: In one embodiment, an embossing drum system comprise: a mandrel having outer surface with an external taper, a primary journal extending from a first end of the mandrel, a secondary journal extending from a second end of the journal, a sleeve having an inner sleeve surface with an internal taper, wherein the sleeve is disposed around the mandrel to form a drum having a substantially constant outer diameter, and a releasable journal support engaging the secondary journal, wherein a sleeve first end of the sleeve having a smallest inner diameter of the sleeve is disposed adjacent the releasable journal support. In one embodiment, a method of drum system maintenance comprises: releasing a journal support on the embossing drum system and sliding the sleeve off of the mandrel and over the secondary journal.

Abstract: Disclosed herein are embossing drums, systems, methods for their use and their maintenance, and films made using the drums. In one embodiment, an embossing drum system can comprise: a mandrel, a primary journal extending from a first end of the mandrel, a secondary journal extending from a second end of the journal, and a seamless sleeve disposed around the mandrel to form a drum. The sleeve comprises a pattern cut into a sleeve outer surface. In one embodiment, a method of making optical films, comprises: introducing a polymer to an embossing drum system, forming the pattern into a surface of the polymer to produce a film, and removing the film from the drum. The embossing drum system comprises a drum with a pattern cut into a drum outer surface. The film has a continuous, seamless pattern having a length that is greater than the drum circumference.

Abstract: A process is provided for continuously embossing a pattern onto a surface of a flowable melt and cooling the flowable melt to provide an embossed film. In one embodiment, the process includes heating a resin to form a flowable melt; discharging the melt into a first nip, an area between an embossing roll and a backside roll; pressing the melt against the embossing roll and the backside roll; and forming a self-supporting film with a surface having an embossed pattern thereon. In one embodiment, the embossing roll is maintained at a temperature greater than the glass transition temperature of the resin material whereas the backside roll is maintained at a temperature less than the glass transition temperature of the resin. In one embodiment, the invention provides an embossed film frangibly fused to a carrier film. In another embodiment, the invention provides an embossed film affixed to a backing film.

Abstract: In one embodiment, a method for making an electroform, comprises passivating a sub-master to form a passivation layer. The passivation comprises contacting at least a surface of the sub-master with a solution comprising an oxidizing agent and applying an anodic current to the sub-master. The surface of the sub-master can be plated with a metal to form a metal layer. The metal layer can be removed to form the electroform.

Abstract: In one embodiment, the method for making an electroform comprises: attaching a sub-master to a first side of a stiffener plate to form a mounted sub-master, wherein the stiffener plate is longer and/or wider than the sub-master such that, when the sub-master is attached to the stiffener plate, the stiffener plate forms a boarder around the sub-master, disposing conductive rim on the stiffener plate in physical contact with the boarder and with the edges of the sub-master, masking edges and a second side of the stiffener plate, passivating the surface to form a passivation layer, plating the surface and non-masked areas of the conductive rim with a metal to form a metal layer, and removing the metal layer to form the electroform.

Abstract: A system for the inspection of and a process for the correction of defects in a microreplicated optical display film manufacturing process. The process steps of manufacturing a master, a plurality of shims from the master, and a multiplicity of display films from each shim are integrated with a systemic defect identification and correction process. Each primary manufacturing step has its own inspection system and correction process where defect information for that step of the process is fed back and analyzed; and from that analysis the subprocess is adjusted to eliminate or reduce the detected defect. The systemic defect is identified as to its source and then fed back and analyzed in the correction step of the respective subprocess in order to cure the root of the defect.

Abstract: Disclosed herein is a method comprising illuminating a microstructured prism, or linear array of prisms of a prism sheet with an incident beam. The method further comprises making measurements of the refracted image of the beam on a measuring device to measure the distance disposed on an opposing side of the prism sheet from the side that the light beam is incident upon. Measurement of two angles of the refracted images of the beam on the ruled scale, measured twice, illuminating the sample at different angles are used in an equation to simultaneously provide the apex angle, the skew angle and the refractive index of the prism sheet.

Abstract: In one embodiment, the film making process can comprise: introducing a plastic melt to a nip between a calendar roll and a resilient roll, passing the plastic melt between the calendar roll and the resilient roll to produce the film, and controlling a roughness of the film by actively cooling an external surface of the resilient roll. In another embodiment, the film making process can comprise: introducing a plastic melt having a melt temperature to a nip between a calendar roll and a resilient roll, passing the plastic melt between the calendar roll and the resilient roll to produce the film, and adjusting a roughness of the film at a constant production rate and a constant nip pressure.

Abstract: A removal assembly and method for removing a submaster from a master is described. A curved tooling surface is arranged within a housing of the assembly. A first array of vacuum cups is attached to the housing adjacent a first end of the curved tooling surface, where the first array of vacuum cups are configured to provide a vacuum grip on a first portion of the submaster. A second array of vacuum cups is attached to the housing adjacent a second end of the curved tooling surface, where the second end opposes the first end, the second array of vacuum cups is configured to provide a vacuum grip on a second portion of the submaster. A rotation mechanism is configured to rotationally support the master as the master is rolled along the curved tooling surface to remove the submaster.

Abstract: A system and process for making non-continuous articles with patterned microstructures. The articles are of high quality and may be used in flat panel display applications. The system and process use a casting roll with a pattern on the surface of the casting roll for patterning a non-continuous microstructure on a surface of the substrate, and a coating device that is adapted to apply a coating to the surface of the substrate in a non-continuous manner so that areas of the substrate that are coated by the coating device correspond to the casting roll pattern.

Abstract: Disclosed are methods for controlling quality in forward gravure printed electroactive layers for electroactive devices. The corresponding electroactive layers made by said methods and electroactive devices comprising said layers are also embodiments of the invention.

Abstract: An apparatus and method of uniformly patterning electro-luminescent layer or layers of an electro-luminescent device such as a photovoltaic cell or an OLED includes solvating and wiping the layer(s) in a tangential direction.

Abstract: A composition comprising a phenylthioethylacrylate, a multifunctional (meth)acrylate, a curing agent, wherein the phenylthioethylacrylate comprises less than about 400 parts per million tin and less than about 2 percent by weight of the corresponding phenylthioethanol. The composition may further comprise at least one unsaturated acid.

Abstract: A curable composition comprising a multifunctional (meth)acrylate, an arylether (meth)acrylate and a surfactant along with optional additives is disclosed. The cured composition displays excellent thermomechanical properties with reduced shrinkage and high refractive index.

Abstract: In one embodiment, a brightness enhancement film comprises: a diffusing film comprising a front surface and a back surface, a coating on the front surface, and light redirecting structures disposed in the coating. The brightness enhancement film is capable of collimating light, and wherein, without the coating, the diffusing film would be capable of spread light passing through the back surface. In another embodiment, the brightness enhancement film comprises: a diffusing film comprising a front surface and a back surface, a coating on the front surface, and light redirecting structures disposed in the coating. The diffusing film has a stress retardation gradient of less than or equal to 50 nm/in, wherein an interval for calculation of the stress retardation gradient is less than 1 inch. The brightness enhancement film is capable of collimating light.

Abstract: A light management film includes a first layer with a thermoplastic resin and a particular phosphonium sulfonate salt, and a second layer formed from a curable composition and having a refractive index of at least 1.5. The light management film exhibits reduced static electricity build-up and reduced dust attraction, making it easier to handle during fabrication of display devices such as the flat panel displays of laptop computers.