Patents by Inventor Matthew S. Stay

Matthew S. Stay has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11413846
    Abstract: Described herein is an article having a microsphere layer comprising a monolayer of microspheres, the monolayer of microspheres comprising a first area substantially free of microspheres and a second area comprising a plurality of randomly-distributed microspheres, wherein the monolayer of microspheres comprises a predetermined pattern, the predetermined pattern comprises at least one of (i) a plurality of the first areas, (ii) a plurality of the second areas, and (iii) combinations thereof; and (b) a bead bonding layer disposed on the microsphere layer, wherein the plurality of microspheres are partially embedded in a first major surface of the bead bonding layer, wherein the article has a retroreflectivity (Ra) of less than 5.0 candelas/lux/square meter. Also disclosed herein are transfer carriers and methods of making the articles and transfer carriers.
    Type: Grant
    Filed: March 29, 2017
    Date of Patent: August 16, 2022
    Assignee: 3M Innovative Properties Company
    Inventors: Christopher B. Walker, Jr., Toheeb B. Alabi, Kui Chen-Ho, John C. Clark, Jeremy P. Gundale, Vivek Krishnan, Alexander J. Kugel, Mikhail L. Pekurovsky, Chris A. Pommer, Matthew S. Stay
  • Publication number: 20220250375
    Abstract: A printing system (200) including a printing roll (220) is provided. The printing roll (220) includes an elastically deformable and compressible inner layer (224) and a thin outer shell (222) to cover the inner layer (224). The thin outer shell (222) includes a pattern of raised print features (223) to receive ink material thereon. The inner layer (224) is softer and thicker than the thin outer shell (222), and optionally, the thin outer shell (222) is removable from the inner layer (224). The inner layer (224) of the printing roll (220) has a thickness, a compression force deflection value and an elastically-deformable compressibility such that the raised print features (223) of the printing roll (220) do not slide or deform with respect to the printed web (2) in an amount to generate a substantially visible dot gain.
    Type: Application
    Filed: July 13, 2020
    Publication date: August 11, 2022
    Inventors: Kara A. Meyers, Shawn C. Dodds, Mikhail L. Pekurovsky, Tyler J. Rattray, James N. Dobbs, Samad Javid, Matthew S. Stay
  • Publication number: 20220183153
    Abstract: A patterned article includes a unitary polymeric layer and a plurality of electrically conductive elements embedded at least partially in the unitary polymeric layer. Each electrically conductive element includes a conductive seed layer having a top major surface and an opposite bottom major surface in direct contact with the unitary polymeric layer, and includes a metallic body disposed on the top major surface of the conductive seed layer. The metallic body has a bottom major surface and at least one sidewall. The bottom major surface contacts the conductive seed layer. Each sidewall is in direct contact with the unitary polymeric layer and extends from the bottom major surface of the metallic body toward or to, but not past, a top major surface of the unitary polymeric layer. The conductive elements may be electrically isolated from one another. Processes for making the patterned article are described.
    Type: Application
    Filed: May 5, 2020
    Publication date: June 9, 2022
    Inventors: Raymond P. Johnston, John J. Sullivan, Matthew C. Messina, Charles D. Hoyle, Jaewon Kim, Haiyan Zhang, Matthew S. Stay, Robert A. Sainati, Kevin W. Gotrik, Kenneth A.P. Meyer, Gregory L. Abraham, Joseph C. Carls, Douglas S. Dunn
  • Publication number: 20220167499
    Abstract: A patterned conductive article 200 includes a substrate 210 including a unitary layer 210-1 and includes a micropattern of conductive traces 220 embedded at least partially in the unitary layer. Each conductive trace extends along a longitudinal direction (y-direction) of the conductive trace and includes a conductive seed layer 230 having a top major surface 232 and an opposite bottom major surface 234 in direct contact with the unitary layer; and a unitary conductive body 240 disposed on the top major surface of the conductive seed layer. The unitary conductive body and the conductive seed layer differ in at least one of composition or crystal morphology. The unitary conductive body has lateral sidewalls 242, 244 and at least a majority of a total area of the lateral sidewalls is in direct contact with the unitary layer.
    Type: Application
    Filed: May 5, 2020
    Publication date: May 26, 2022
    Inventors: Raymond P. Johnston, Kevin W. Gotrik, John J. Sullivan, Kenneth A.P. Meyer, Joseph C. Carls, Haiyan Zhang, Gregory L. Abraham, Matthew S. Stay
  • Patent number: 11279859
    Abstract: Methods of passivating an adhesive via printing an ink onto a release liner, and adhesive articles or products made by the same are provided. An ink pattern is printed onto a release liner to form a pattern of features. The features are at least partially embedded in an adhesive layer such that when the release liner is peeled from the adhesive layer, the passivation features remain with the layer of adhesive to form selected areas having adjusted adhesive functionality. Articles including the passivated adhesive on a release liner are also disclosed.
    Type: Grant
    Filed: November 29, 2017
    Date of Patent: March 22, 2022
    Assignee: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Matthew R. D. Smith, Matthew S. Stay, Mikhail L. Pekurovsky, Daniel J. Theis, Thomas J. Metzler, Shawn C. Dodds
  • Patent number: 11280942
    Abstract: An exposed-lens retroreflective article including a binder layer and a plurality of retroreflective elements. Each retroreflective element includes a transparent microsphere partially embedded in the binder layer. At least some of the retroreflective elements comprise at least one color layer comprising a bi-layer structure.
    Type: Grant
    Filed: October 25, 2018
    Date of Patent: March 22, 2022
    Assignee: 3M Innovative Properties Company
    Inventors: Daniel J. Schmidt, Matthew S. Stay, Michael A. McCoy, Kui Chen-Ho, Richard S. Buckanin
  • Patent number: 11284521
    Abstract: A composite article includes a conductive layer with nanowires on at least a portion of a flexible substrate, wherein the conductive layer has a conductive surface. A patterned layer of a low surface energy material is on a first region of the conductive surface. An overcoat layer free of conductive particulates is on a first portion of a second region of the conductive surface unoccupied by the patterned layer. A via is in a second portion of the second region of the conductive surface between an edge of the patterned layer of the low surface energy material and the overcoat layer. A conductive material is in the via to provide an electrical connection to the conductive surface.
    Type: Grant
    Filed: June 22, 2016
    Date of Patent: March 22, 2022
    Assignee: 3M INNOVATIVE PROPERTIES, COMPANY
    Inventors: Matthew S. Stay, Shawn C. Dodds, Ann M. Gilman, Mikhail L. Pekurovsky, Daniel J. Theis, Matthew R. D. Smith
  • Publication number: 20220048286
    Abstract: Methods, apparatuses and systems for printing an ink pattern on a moving web via die cutting are provided. A die roll including an inked pattern of die blades contacts a substrate to cut or cleave the substrate surface. While the die blades withdraw from the substrate, at least some of the ink transfers from the die blades to the cut substrate to form an ink pattern.
    Type: Application
    Filed: October 16, 2019
    Publication date: February 17, 2022
    Inventors: Thomas J. Metzler, Kara A. Meyers, Saagar A. Shah, Mikhail L. Pekurovsky, Matthew S. Stay, Shawn C. Dodds, Kevin T. Reddy, John T. Strand, Daniel J. Theis, Jeremy O. Swanson, Daniel M. Lentz
  • Publication number: 20220045415
    Abstract: A waveguide for receiving an incident electromagnetic wave (EMW) having an operating frequency ? includes an array of spaced apart unit cells arranged along the waveguide. The unit cells are configured to resonantly couple to the incident EMW and radiate an EMW at the operating frequency propagating inside and along the waveguide. Each unit cell is configured to couple to the incident EMW with a first coupling efficiency and includes a dielectric body configured to couple to the incident EMW with a second coupling efficiency and one or more metal layers disposed on and partially covering the dielectric body. The second coupling efficiency is substantially smaller than the first coupling efficiency. A communication system includes the waveguide and a transceiver configured to emit an EMW having the operating frequency ?.
    Type: Application
    Filed: October 22, 2021
    Publication date: February 10, 2022
    Inventors: Jaewon Kim, Dipankar Ghosh, Craig W. Lindsay, Matthew S. Stay
  • Publication number: 20210379887
    Abstract: A printing system is provided. The printing system (300) includes a printing roll (310) having a rigid printing pattern (312) on a surface thereof configured to receive an ink material (330); and an inking roll (320) positioned adjacent to the printing roll. The inking roll includes an elastically deformable surface and a number of cells (324) disposed on the elastically deformable surface. A method of printing is also provided. The method includes (a) inking at least a portion of a rigid printing pattern (312) on a surface of a printing roll (310) by contacting the rigid printing pattern with an inking roll (320); and (b) contacting the rigid printing pattern with a substrate (350), transferring the ink material from the rigid printing pattern to a surface of the substrate. Printing systems and methods can achieve higher printing feature resolutions than typically achievable via flexographic printing.
    Type: Application
    Filed: October 14, 2019
    Publication date: December 9, 2021
    Inventors: Matthew R. D. Smith, Shawn C. Dodds, Mikhail L. Pekurovsky, Thomas J. Metzler, Matthew S. Stay, Kara A. Meyers, Samad Javid
  • Patent number: 11189898
    Abstract: A waveguide and a communication system including the waveguide are described. The waveguide is configured to propagate an electromagnetic wave having an operating frequency along the waveguide. The waveguide includes a substrate having a first dielectric constant, and an array of spaced apart unit cells at least partially embedded in the substrate and arranged along the waveguide. Each of a plurality of the unit cells in the array of spaced apart unit cells has a first transmission parameter S121 having a lowest resonant frequency ?1 and includes a dielectric body and one or more electrically conductive layers disposed on and partially covering the dielectric body. The dielectric body has a second dielectric constant greater than the first dielectric constant at the operating frequency and has a second transmission parameter S221 having a lowest resonant frequency ?2 greater than ?1.
    Type: Grant
    Filed: October 22, 2018
    Date of Patent: November 30, 2021
    Assignee: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Jaewon Kim, Dipankar Ghosh, Craig W. Lindsay, Matthew S. Stay
  • Publication number: 20210325585
    Abstract: The disclosed patterned wavelength-selective material and process for making the patterned wavelength-selective material uses selectively located barriers to the adhesive regions. A structurally weak wavelength-selective material includes portions that contact the adhesive regions and break to remain in contact with the adhesive. The wavelength-selective material does not contact the adhesive regions covered by the barrier and is removed leaving a wavelength-selective film in a pattern at the adhesive regions.
    Type: Application
    Filed: July 19, 2019
    Publication date: October 21, 2021
    Inventors: Kui CHEN-HO, Douglas S. DUNN, Matthew S. STAY, Daniel J. THEIS, John T. STRAND, Shawn C. DODDS, Thomas J. METZLER, Kevin W. GOTRIK, Scott J. JONES
  • Publication number: 20210294005
    Abstract: Optical films are described. In particular, optical films including a broadband polymeric multilayer optical reflector and a discontinuous transparent coating disposed on the broadband multilayer optical reflector, where the discontinuous transparent coating includes an array of dots are described. Such films may provide reduced coefficients of friction while still having high specular reflectivity.
    Type: Application
    Filed: July 15, 2019
    Publication date: September 23, 2021
    Inventors: Jeremy O. Swanson, Matthew S. Stay, Matthew R. D. Smith
  • Patent number: 11114599
    Abstract: Electronic devices including a layer of polymeric material and solid semiconductor dies partially embedded in the layer are provided. The dies have first ends projecting away from the first major surface of the layer. The electronic devices can be formed by sinking the first ends of the dies into a major surface of a liner. A flowable polymeric material is filled into the space between the dies and solidified to form the layer of polymeric material. The first ends of the dies are exposed by delaminating the liner from the first ends of the dies. Electrical conductors are provided on the layer to connect the first ends of the dies.
    Type: Grant
    Filed: March 22, 2018
    Date of Patent: September 7, 2021
    Assignee: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Ankit Mahajan, Mikhail L. Pekurovsky, Matthew S. Stay, Shawn C. Dodds, Thomas J. Metzler, Matthew R. D. Smith, Saagar A. Shah, Jae Yong Lee, James F. Poch, Roger W. Barton
  • Publication number: 20210222033
    Abstract: Modified adhesive layers are prepared by contacting an adhesive layer to a modified microstructured release liner. The modified release liner has a release layer surface with a set of microstructured depressions and a discontinuous pattern of ink material located on the surface of the release layer. A portion of the discontinuous pattern of ink material overlaps with and is located within some of the depressions. The ink material comprises a non-adhesive but adhesively transferrable material, or an adhesive material. Upon removal of the adhesive from the release liner, the ink material transfers to the adhesive surface.
    Type: Application
    Filed: June 6, 2019
    Publication date: July 22, 2021
    Inventors: Kui Chen-Ho, Patrick J. Yeshe, Matthew S. Stay, Matthew R. D. Smith, Anish Kurian, Ross E. Behling
  • Publication number: 20210194104
    Abstract: A waveguide and a communication system including the waveguide are described. The waveguide is configured to propagate an electromagnetic wave having an operating frequency along the waveguide. The waveguide includes a substrate having a first dielectric constant, and an array of spaced apart unit cells at least partially embedded in the substrate and arranged along the waveguide. Each of a plurality of the unit cells in the array of spaced apart unit cells has a first transmission parameter S121 having a lowest resonant frequency ?1 and includes a dielectric body and one or more electrically conductive layers disposed on and partially covering the dielectric body. The dielectric body has a second dielectric constant greater than the first dielectric constant at the operating frequency and has a second transmission parameter S221 having a lowest resonant frequency ?2 greater than ?1.
    Type: Application
    Filed: October 22, 2018
    Publication date: June 24, 2021
    Inventors: Jaewon Kim, Dipankar Ghosh, Craig W. Lindsay, Matthew S. Stay
  • Publication number: 20210161018
    Abstract: Methods of making metal patterns on flexible substrates are provided. Releasable solid layer is selectively formed on a patterned surface of the flexible substrate by applying a liquid solution thereon. Metal patterns on the flexible substrate can be formed by removing the releasable solid layer after metallization. In some cases, the releasable solid layer can be transferred from the patterned surface to a transfer layer where the metal patterns are formed.
    Type: Application
    Filed: June 27, 2019
    Publication date: May 27, 2021
    Inventors: Henrik B. van Lengerich, Matthew S. Stay, Caleb T. Nelson, David J. Tarnowski, David J. Rowe, Edwin L. Kusilek
  • Patent number: 10971468
    Abstract: Processes for automatic registration between a solid circuit die and electrically conductive interconnects, and articles or devices made by the same are provided. The solid circuit die is disposed on a substrate with contact pads aligned with channels on the substrate. Electrically conductive traces are formed by flowing a conductive liquid in the channels toward the contact pads to obtain the automatic registration.
    Type: Grant
    Filed: November 16, 2017
    Date of Patent: April 6, 2021
    Assignee: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Ankit Mahajan, Mikhail L. Pekurovsky, Matthew S. Stay, Daniel J. Theis, Ann M. Gilman, Shawn C. Dodds, Thomas J. Metzler, Matthew R. D. Smith, Roger W. Barton, Joseph E. Hernandez, Saagar A. Shah, Kara A. Meyers, James Zhu, Teresa M. Goeddel, Lyudmila A. Pekurovsky, Jonathan W. Kemling, Jeremy K. Larsen, Jessica Chiu, Kayla C. Niccum
  • Patent number: 10845514
    Abstract: Provided herein are retroreflective colored article having a predetermined pattern of beaded and unbeaded regions and at least one polymeric color layer (130) covering at least a portion of the beaded and unbeaded regions, a reflector layer (140) covering the colour layer, and a carrier (150). Also disclosed are methods for making the articles.
    Type: Grant
    Filed: September 24, 2015
    Date of Patent: November 24, 2020
    Assignee: 3M Innovative Properties Company
    Inventors: Kui Chen-Ho, Matthew S. Stay, Ying Xia, Syud M. Ahmed, Cordell M. Hardy, Shri Niwas, Michael A. McCoy, Mikhail L. Pekurovsky
  • Patent number: 10831233
    Abstract: A method of patterning a conductive layer to form transparent electrical conductors that does not require etching is disclosed. The method includes peeling a strippable polymer layer from a substrate coated with the conductive layer to pattern the conductive layer. In some embodiments, a resist matrix material is patterned over the conductive layer to prevent removal of the conductive layer beneath the resist matrix material. In other embodiments, a liner having a pressure sensitive adhesive surface is brought into contact with the patterned strippable polymer material to remove both the patterned strippable polymer material and the conductive layer beneath it.
    Type: Grant
    Filed: February 21, 2019
    Date of Patent: November 10, 2020
    Assignee: 3M INNOVATIVE PROPERTIES COMPANY
    Inventors: Shawn C. Dodds, Matthew S. Stay, Mikhail L. Pekurovsky, Matthew H. Frey, Mark J. Pellerite, John P. Baetzold