Abstract: A process for applying a coating material onto a substrate as a non-uniform discontinuous pattern of coating material, the method including the present disclosure describes a method of applying a coating material onto a substrate, including providing a first distribution manifold having a cavity and a multiplicity of first dispensing outlets in fluid communication with the cavity, creating relative motion between a substrate and the dispensing outlets in a first direction; dispensing a first coating material from the dispensing outlets while maintaining the relative motion and translating the multiplicity of dispensing outlets in a second direction non-parallel to the first direction, and varying a rate of dispensing of the first coating material in a predetermined fashion to form a discontinuous pattern of the first coating material on a major surface of the substrate. Useful non-uniformly patterned coated articles can be prepared using the process.

Abstract: A method of applying a pattern to a nonplanar surface. A stamp has a major surface with pattern elements having a lateral dimension of greater than 0 and less than about 5 microns. The major surface of the stamp has a functionalizing molecule with a functional group selected to chemically bind to the nonplanar surface. The stamp is positioned to initiate rolling contact with the nonplanar surface, and contacts the nonplanar surface to form a self-assembled monolayer (SAM) of the functionalizing material thereon and impart the arrangement of pattern elements thereto. The major surface of the stamp is translated with respect to the nonplanar surface such that: a contact pressure is controlled at an interface between the stamping surfaces and the nonplanar surface, and a contact force at the interface is allowed to vary while the stamping surfaces and the nonplanar surface are in contact with each other.

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 method of applying a pattern to a nonplanar surface. A stamp has a major surface with pattern elements having a lateral dimension of greater than 0 and less than about 5 microns. The major surface of the stamp has a functionalizing molecule with a functional group selected to chemically bind to the nonplanar surface. The stamp is positioned to initiate rolling contact with the nonplanar surface, and contacts the nonplanar surface to form a self-assembled monolayer (SAM) of the functionalizing material thereon and impart the arrangement of pattern elements thereto. The major surface of the stamp is translated with respect to the nonplanar surface such that: a contact force is controlled at an interface between the stamping surfaces and the nonplanar surface, and the contact pressure at the interface is allowed to vary while the stamping surfaces and the nonplanar surface are in contact with each other.

Abstract: Coating apparatuses and methods are provided for dispensing coatings with various shapes. The coating apparatus includes a coating die body including a cavity and an opening on a dispensing side thereof. One or more movable components are disposed on the dispensing side of the die body to define at least a portion of a dispensing slot adjacent the opening of the cavity. The one or more movable components are movable with respect to the opening to allow a width of the dispensing slot along a cross direction to be dynamically adjustable.

Abstract: Coating apparatuses and methods are provided for direct coatings with various shapes. The coating apparatus includes a die body with one or more bores. One or more cams are pivotally mounted within the bores and have one or more recessed areas formed into the respective peripheral surfaces thereof. The one or more cams are rotatable within the die body to dynamically, independently vary the width or shape of the respectively dispensed one or more fluid coatings.

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

Abstract: A method of patterning a cylindrical tool, including providing a stamp including a base and a layer of solid state ionic conductor thereon, applying a negative of a predetermined pattern of features on a major surface of the solid state ionic conductor, providing a cylindrical tool having a metallic surface positioned proximate the stamp, and applying an electric field between the metallic surface and a cathode while moving the stamp against the metallic surface in rolling line contact so as to impart the predetermined pattern of features onto the metallic surface, wherein the cathode is either the base or a conductive element positioned adjacent to the base. The positive of the predetermined pattern of features may include a multiplicity of nano-sized features.

Abstract: A process for applying a coating material onto a substrate as a non-uniform discontinuous pattern of coating material, the method including the present disclosure describes a method of applying a coating material onto a substrate, including providing a first distribution manifold having a cavity and a multiplicity of first dispensing outlets in fluid communication with the cavity, creating relative motion between a substrate and the dispensing outlets in a first direction; dispensing a first coating material from the dispensing outlets while maintaining the relative motion and translating the multiplicity of dispensing outlets in a second direction non-parallel to the first direction, and varying a rate of dispensing of the first coating material in a predetermined fashion to form a discontinuous pattern of the first coating material on a major surface of the substrate. Useful non-uniformly patterned coated articles can be prepared using the process.

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: Electrically conductive patterns formed on a substrate are provided with a reduced visibility. A region of a major surface of the substrate is selectively roughened to form a roughened pattern on the major surface of the substrate. Electrically conductive traces are directly formed on the roughened region and are conformal with the roughened pattern on the major surface of the substrate.

Abstract: Coating apparatuses and methods are provided for direct coatings with various shapes. The coating apparatus includes a die body with one or more bores. One or more cams are pivotally mounted within the bores and have one or more recessed areas formed into the respective peripheral surfaces thereof. The one or more cams are rotatable within the die body to dynamically, independently vary the width or shape of the respectively dispensed one or more fluid coatings.

Abstract: A method of patterning a cylindrical tool, including providing a stamp including a base and a layer of solid state ionic conductor thereon, applying a negative of a predetermined pattern of features on a major surface of the solid state ionic conductor, providing a cylindrical tool having a metallic surface positioned proximate the stamp, and applying an electric field between the metallic surface and a cathode while moving the stamp against the metallic surface in rolling line contact so as to impart the predetermined pattern of features onto the metallic surface, wherein the cathode is either the base or a conductive element positioned adjacent to the base. The positive of the predetermined pattern of features may include a multiplicity of nano-sized features.

Abstract: An apparatus for steering a web, including a web path having at least one steering roller and an exit roller, each having a mount; wherein the steering roller(s) each have an axis of rotation and wherein the mounts for the steering roller(s) can pivot those axes with a total of two degrees of freedom. An array comprising a plurality of sensors for monitoring the position of the web is present connected to a controller so as to determine the position and angular orientation of the web. The controller adjusts the pivot(s) of the mount(s) so as to control the angular orientation and the lateral position of the web at a particular point along the web path.

Abstract: Coating apparatuses and methods are provided for dispensing coatings with various shapes. The coating apparatus includes a coating die body including a cavity and an opening on a dispensing side thereof. One or more movable components are disposed on the dispensing side of the die body to define at least a portion of a dispensing slot adjacent the opening of the cavity. The one or more movable components are movable with respect to the opening to allow a width of the dispensing slot along a cross direction to be dynamically adjustable.

Abstract: A manufacturing system includes a sensing system that provides high-resolution feedback for web guiding and tension control. The system may be especially useful for web material that is manufactured to include micro-replicated structures with micron size scale. A micro-replication station forms a pattern of micro-replicated lenses on a web material. The sensing system illuminates a measurement area on the web material and detects an angular distribution of light exiting a set of the micro-replicated lenses within the first measurement area. A control system that adjusts at least one process control parameter of the transport system based on the detected angular distribution.

Abstract: A viscoelastic adhesive composition is provided, wherein at a dispensing temperature of between 35° C. and 120° C., the viscoelastic adhesive composition can be discretely dispensed and has a tan delta of at least 1 as determined by dynamic mechanical analysis at a frequency of 1 Hz and a complex viscosity of less than 5×103 Pascal-sec at a complex viscosity of less than 5×103Pascal-sec at a frequency of about 10 radians s?1. Such adhesives have been found useful in forming optical assemblies for producing display panels used in a variety of electronic devices.

Abstract: A process including positioning a coating head to define a gap between a first external opening in flow communication with a source of a first coating liquid, and a major surface of a substrate; creating relative motion between the first coating head and the substrate; dispensing a pre-determined quantity of the first coating liquid to form a discrete patch in a predetermined position on the substrate's major surface; positioning a second coating head to define a gap between a second external opening in flow communication with a source of a second coating liquid and a major surface of the patch; creating relative motion between the second coating head and the substrate, and dispensing a pre-determined quantity of the second coating liquid to form a discontinuous pattern on the patch's major surface. The first and optionally the second coating liquids exhibit a viscosity as dispensed of at least 1 Pascal-sec.

Abstract: An apparatus for steering a web, including a web path having at least one steering roller and an exit roller, each having a mount; wherein the steering roller(s) each have an axis of rotation and wherein the mounts for the steering roller(s) can pivot those axes with a total of two degrees of freedom. An array comprising a plurality of sensors for monitoring the position of the web is present connected to a controller so as to determine the position and angular orientation of the web. The controller adjusts the pivot(s) of the mount(s) so as to control the angular orientation and the lateral position of the web at a particular point along the web path.

Abstract: An apparatus (20) for steering a web (22), including a web path having at least one steering roller (24) and an exit roller (26), each having a mount; wherein the steering roller(s) (26) each have an axis of rotation and wherein the mounts for the steering roller(s) (26) can pivot those axes with a total of two degrees of freedom. An array (30) comprising a plurality of sensors (30a) for monitoring the position of the web (22) is present connected to a controller so as to determine the position and angular orientation of the web (22). The controller adjusts the pivot(s) of the mount(s) so as to control the angular orientation and the lateral position of the web (22) at a particular point along the web path.