Abstract: Wet-on-wet coating processes are provided to produce multilayer articles. First and second coating materials are sequentially applied on to a structured substrate surface to form a skin layer directly over the structured substrate surface and a bulk layer over the skin layer. The conformability of the skin layer can be adjusted to provide desired surface and bulk properties.

Abstract: Wet-on-wet coating processes are provided to produce multilayer articles. First and second coating materials are sequentially applied on to a structured substrate surface to form a skin layer directly over the structured substrate surface and a bulk layer over the skin layer. The conformability of the skin layer can be adjusted to provide desired surface and bulk properties.

Abstract: Methods and apparatuses for applying coatings on a baggy web are provided. A Mayer rod and a back-up roll engage with each other to form a nip. The back-up roll has a deformable inner layer with a surface thereof covered by a deformable outer layer. The Mayer rod and the flexible web at a contacting area are impressed into the back-up roll with a machine-direction nip width W and a nip engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: A powder deagglomerator includes a vertical flow chamber, a powder inlet tube, and an ultrasonic horn vibrationally coupled to an ultrasonic transducer. The vertical flow chamber includes an outer wall, powder outlet port, and a mounting port sealably engaging an ultrasonic horn. The powder inlet tube extends through the outer wall and is aligned to dispense agglomerated powder in a gaseous stream downward onto a distal end of the ultrasonic horn. A method of using the powder deagglomerator to deagglomerate a powder is also disclosed.

Abstract: Ultrathin and flexible electrical devices including circuit dies such as, for example, a capacitor chip, a resistor chip, and/or an inductor chip, and methods of making and using the same are provided. Circuit dies are attached to a major surface of a flexible substrate having channels Electrically conductive traces are formed in the channels, self-aligned with the circuit dies, and in direct contact with the bottom surface of the circuit dies.

Abstract: A powder deagglomerator comprises a vertical flow chamber, a powder inlet tube, and an ultrasonic horn vibrationally coupled to an ultrasonic transducer. The vertical flow chamber includes an outer wall, powder outlet port, and a mounting port sealably engaging an ultrasonic horn. The powder inlet tube extends through the outer wall and is aligned to dispense agglomerated powder in a gaseous stream downward onto a distal end of the ultrasonic horn. A method of using the powder deagglomerator to deagglomerate a powder is also disclosed.

Abstract: A powder jet pump that is effective for creating a smoothly flowing gas stream with well dispersed particles.

Abstract: Methods and apparatuses for applying coatings on a baggy web are provided. A Mayer rod and a back-up roll engage with each other to form a nip. The back-up roll has a deformable inner layer with a surface thereof covered by a deformable outer layer. The Mayer rod and the flexible web at a contacting area are impressed into the back-up roll with a machine-direction nip width W and a nip engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: Methods for using a hollow, rotating stencil roll to deposit flowable dry powder particles onto a moving substrate and to adhesively bond the particles to a pressure-sensitive adhesive surface of the substrate.

Abstract: A powder-rubbing apparatus comprises: a rotatable rubbing roll having a rotational axis; a substrate path; an oscillating mechanism for oscillating the rotatable rubbing roll along the rotational axis; and a powder coating die comprising an inlet port in fluid communication with an outlet port disposed adjacent to the substrate path. The substrate frictionally contacts the rotatable rubbing roll within a rubbing zone. A dispenser for dispensing gas-borne powder is in fluid communication with the inlet port of the powder coating die. The dispenser is aligned such that at least a portion of a gas-borne powder dispensed from the powder coating die is deposited directly onto at least one of the rotatable rubbing roll or the substrate and conveyed into the rubbing zone. A method of using the powder-rubbing apparatus and a powder-rubbed web preparable thereby are also disclosed.

Abstract: A method comprises exposing a particle coating disposed on a thermally-softenable film to a modulated source of electromagnetic radiation. The particle coating comprises distinct particles that are not covalently bonded to each other, and are not retained in a binder material other than the thermally-softenable film. Articles made by the method are also disclosed.

Abstract: Methods for using a hollow, rotating stencil roll to deposit flowable dry powder particles onto a moving substrate and to attach the particles to the substrate.

Abstract: Methods for using a hollow, rotating stencil roll to deposit flowable dry powder particles onto a moving substrate and to attach the particles to the substrate.

Abstract: Methods for using a hollow, rotating stencil roll to deposit flowable dry powder particles onto a moving substrate and to adhesively bond the particles to a pressure-sensitive adhesive surface of the substrate.