Abstract: A web-handling machine frame, at least partially built from reconfigurable interconnected blocks having precision alignment points. From such blocks, modular equipment web-handling lines for web-handling operations can be constructed ad hoc with their shaft mounted web-contacting devices in tram without the need for separate alignment procedures.

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 system and method for controlling curl in multi-layer webs. The method can include providing a coated web, curing the coating to form a multi-layer web, and stretching the web during curing of the coating. Some coatings shrink at least partially when cured such that curing the coating induces a strain in the multi-layer web. Stretching the web occurs during curing to induce an opposing strain that at least partially counteracts the strain induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure the coating, and can further include a web stretching section, which can be located proximate the curing section and can be substantially coincident with the curing section, such that the web is stretched while the coating is cured.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, curing the coating to form a multi-layer web, and stretching the web during curing of the coating. Some coatings shrink at least partially when cured such that curing the coating induces a strain in the multi-layer web. Stretching the web occurs during curing to induce an opposing strain that at least partially counteracts the strain induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure the coating, and can further include a web stretching section, which can be located proximate the curing section and can be substantially coincident with the curing section, such that the web is stretched while the coating is cured.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, bending the web to induce a strain or pre-curl in the web, and curing the coating to form a multi-layer web. Some coatings at least partially shrink when cured such that curing the coating induces a curl in the multi-layer web. Bending the web occurs prior to curing the coating, and the pre-curl can be configured to at least partially counteract the curl induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure a coating, and can further include a web bending section configured to bend the web to induce a strain in the web. The web bending section can be positioned upstream of the curing section such that the web is bent prior to the coating being cured.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, bending the web to induce a strain or pre-curl in the web, and curing the coating to form a multi-layer web. Some coatings at least partially shrink when cured such that curing the coating induces a curl in the multi-layer web. Bending the web occurs prior to curing the coating, and the pre-curl can be configured to at least partially counteract the curl induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure a coating, and can further include a web bending section configured to bend the web to induce a strain in the web. The web bending section can be positioned upstream of the curing section such that the web is bent prior to the coating being cured.

Abstract: A system for flexing a web is disclosed. The web passes over two co-rotating members, such as rollers or belts, which are separated by a small adjustable gap. The web travels around the first rotating member, is peeled off in the vicinity of the gap, bent back on itself in a small radius and reattached on the second co-rotating member. The location of the small radius is fixed with a closed loop control system sensing the radius location and controlling the relative velocity of the two members. Strain in the web is adjusted with the size of the small radius, which is controlled by the adjustable gap and radius location.

Abstract: A system for flexing a web is disclosed. The web passes over two co-rotating members, such as rollers or belts, which are separated by a small adjustable gap. The web travels around the first rotating member, is peeled off in the vicinity of the gap, bent back on itself in a small radius and reattached on the second co-rotating member. The location of the small radius is fixed with a closed loop control system sensing the radius location and controlling the relative velocity of the two members. Strain in the web is adjusted with the size of the small radius, which is controlled by the adjustable gap and radius location.

Abstract: Methods and systems for forming layered electronic devices on a flexible, elongated substrate are described. The layered electronic devices include at least one electronically or optically active layer. Deposition of one more layers of the electronic devices occurs as the flexible substrate is moved through one or more deposition stations. At each deposition station the substrate is aligned with an aperture mask having apertures arranged in a pattern. The aperture mask and the substrate are brought into proximity over a portion of a circumference of a rotating drum. A layer of the layered electronic devices is formed by deposition of material through the apertures of the aperture mask. At each deposition station, registration between at least two layers of the layered electronic devices is maintained.

Abstract: An apparatus and method for flexing a web is disclosed. The web passes over two co-rotating members, such as rollers or belts, which are separated by a small adjustable gap. The web travels around the first rotating member, is peeled off in the vicinity of the gap, bent back on itself in a small radius and reattached on the second co-rotating member. The location of the small radius is fixed with a closed loop control system sensing the radius location and controlling the relative velocity of the two members. Strain in the web is adjusted with the size of the small radius, which is controlled by the adjustable gap and radius location.

Abstract: An apparatus and method for flexing a web is disclosed. The web passes over two co-rotating members, such as rollers or belts, which are separated by a small adjustable gap. The web travels around the first rotating member, is peeled off in the vicinity of the gap, bent back on itself in a small radius and reattached on the second co-rotating member. The location of the small radius is fixed with a closed loop control system sensing the radius location and controlling the relative velocity of the two members. Strain in the web is adjusted with the size of the small radius, which is controlled by the adjustable gap and radius location.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, bending the web to induce a strain or pre-curl in the web, and curing the coating to form a multi-layer web. Some coatings at least partially shrink when cured such that curing the coating induces a curl in the multi-layer web. Bending the web occurs prior to curing the coating, and the pre-curl can be configured to at least partially counteract the curl induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure a coating, and can further include a web bending section configured to bend the web to induce a strain in the web. The web bending section can be positioned upstream of the curing section such that the web is bent prior to the coating being cured.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, curing the coating to form a multi-layer web, and stretching the web during curing of the coating. Some coatings shrink at least partially when cured such that curing the coating induces a strain in the multi-layer web. Stretching the web occurs during curing to induce an opposing strain that at least partially counteracts the strain induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure the coating, and can further include a web stretching section, which can be located proximate the curing section and can be substantially coincident with the curing section, such that the web is stretched while the coating is cured.

Abstract: A pattern of material is continuously deposited onto a substrate. The substrate and a mask are continuously brought together over a portion of a drum where a deposition source emits material. The mask includes apertures that form a pattern, and the material from the deposition source passes through the pattern of the mask and collects onto the substrate to form the pattern of material. The elongation and the transverse position of the substrate and the mask may be controlled. Pattern elements of the substrate and of the mask may be sensed in order to adjust the elongation and/or the transverse position of the substrate and/or mask to maintain a precise registration. Furthermore, the apertures may have a least dimension on the order of 100 microns or less to thereby create features on the substrate having least dimensions on the order of 100 microns or less.

Abstract: A method of controlling a moving web in relation to a selected transverse position comprising positioning a first positioning guide proximate a second positioning guide wherein the second positioning guide has a mechanism for positioning the web having minimal backlash. The web is passed through the first positioning guide and the second positioning guide. A sensor detects the transverse position of the moving web at the second positioning guide. The sensor transmits the transverse location of the web at the second positioning guide to a controller. The controller manipulates a zero-backlash actuator wherein the zero-backlash actuator is coupled to the second positioning guide such that the transverse position of the web is controllable to within a preselected dimension of the selected transverse position.

Abstract: The method of the present invention provides a way to make rolls of high shear strength pressure sensitive adhesive tapes with a transparent to the core appearance in a relatively short time and without the need to subject the rolls to additional method steps. Moreover, the present invention achieves such transparent to the core appearance by sufficiently wetting-out the adhesive on the tape backing to remove microscopic air bubbles entrapped within the harder and less deformable high shear strength adhesive layers. The method comprises a rewinding method and is characterized by the use of a pack roll during rewinding to provide a sufficiently high contact pressure to the non-adhesive side of the tape substantially at the application point of the tape to the tape roll. In one aspect, a sufficient contact pressure is provided by the pack roll so that the pressure sensitive adhesive tape rolls are made with a transparent to the core appearance at the time of the rewinding step.

Abstract: A device and method for determining the radial pressure profile of a wound roll of material uses internal and external sensors to measure the time of flight of an acoustic wave induced within the roll by sharply impacting the surface, or by impacting a member in contact with the surface. The wave measurements are then fed to a computer which uses a modification of Hakiel's model to compute the radial pressure profile.

Abstract: An open tube apparatus and method for continuously producing a rotating elongate strip of material are disclosed. An extrusion die continuously extrudes flowable material to form an open tube with a central longitudinal cavity and a transport mechanism includes a plurality of drive rollers which engage and pull the tube downline. A driver rotates the extrusion die and transport mechanism. A tube cutter, which is offset at an angle with respect to the downline direction and defines the open end of the tube, cuts the tube into a continuous elongate web of the desired width as the tube moves downline. An air seal seals the tube cavity to prevent air from escaping through the open end of the cavity, and a tube pressurizer controls air pressure in the central longitudinal cavity of the tube to expand the tube laterally outwardly.

Abstract: A constraining structure for an open tube apparatus for continuously producing a rotating elongate strip of material is disclosed. The constraining structure controls expansion of an extruded blown film tube to a desired outer diameter range after the tube is formed. The constraining structure includes a casing positionable around the tube, and an annular sleeve in the casing having a generally cylindrical central passageway adapted to receive the tube to permit movement of the tube along its longitudinal axis in a downline direction. The casing and the sleeve walls define a gas chamber with pressurized gas separate from the passageway. The gas layer along the inner surface of the sleeve is at a sufficiently large pressure to constrain the tube to the desired outer diameter while the tube solidifies and to prevent the tube from contacting the sleeve.