48 results about "Roll-to-roll processing" patented technology

This invention comprises deposition of thin film photovoltaic junctions on metal substrates which can be heat treated following deposition in a continuous fashion without deterioration of the metal support structure. In a separate operation an interconnection substrate structure is produced in a continuous roll-to-roll fashion. In this way the interconnection substrate structure can be uniquely formulated from polymer-based materials since it does not have to endure high temperature exposure. Cells comprising the metal foil supported photovoltaic junctions are then laminated to the interconnection substrate structure. Conductive interconnections are deposited to complete the array. The conductive interconnections can be accomplished with a separately prepared interconnection component. The interconnected array is produced using continuous roll-to-roll processing which avoids the need to use the expensive and intricate material removal operations currently taught in the art to achieve electrical interconnections among arrays of photovoltaic cells.

Photovoltaic modules comprising back-contact solar cells manufactured using monolithic module assembly techniques comprising a flexible circuit comprising a back sheet and a patterned metallization. The module may comprise busses in electrical contact with the patterned metallization to extract the current. The module may alternatively comprise multilevel metallizations. Interlayer dielectric comprising islands or dots relieves stresses due to thermal mismatch. The use of multiple cord plates enables flexible circuit layouts, thus optimizing the module. The modules preferably comprise a thermoplastic encapsulant and / or hybrid adhesive / solder materials. An ultrathin moisture barrier enables roll-to-roll processing.

This invention comprises deposition of thin film photovoltaic junctions on metal substrates which can be heat treated following deposition in a continuous fashion without deterioration of the metal support structure. In a separate operation an interconnection substrate structure is produced in a continuous roll-to-roll fashion. In this way the interconnection substrate structure can be uniquely formulated from polymer-based materials since it does not have to endure high temperature exposure. Cells comprising the metal foil supported photovoltaic junctions are then laminated to the interconnection substrate structure. Conductive interconnections are deposited to complete the array. The conductive interconnections can be accomplished with a separately prepared interconnection component. The interconnected array is produced using continuous roll-to-roll processing which avoids the need to use the expensive and intricate material removal operations currently taught in the art to achieve electrical interconnections among arrays of photovoltaic cells.

One aspect of the invention relates to a new dual-layered construction that provides advantageous oxygen barrier properties. Another aspect of the invention is a multilayer film that has advantageous oxygen and / or moisture barrier properties. The film may be fully-organic. The film may also be primarily water-based. At least some embodiments of the film can be produced using wide-web, roll-to-roll processing. Specific example applications for uses of the film include dried food, pharmaceuticals, liquids, lidstock, cheese, meat, health & beauty, and coffee packaging, among many others. Another aspect of the invention is a water-based, fast curing coating composition that provides a high barrier against oxygen and moisture permeation. In one embodiment, the coating comprises special PVDC copolymer compositions with good oxygen barrier (OTR<1 CC / M<2 >day) and high moisture barrier (MVTR<0.5 G / M<2 >day). As one example, the coating may be used to produce a flexible, high clarity, barrier film for packaging.

This invention comprises deposition of thin film photovoltaic junctions on metal substrates which can be heat treated following deposition in a continuous fashion without deterioration of the metal support structure. In a separate operation an interconnection substrate structure is produced in a continuous roll-to-roll fashion. In this way the interconnection substrate structure can be uniquely formulated from polymer-based materials since it does not have to endure high temperature exposure. Cells comprising the metal foil supported photovoltaic junctions are then laminated to the interconnection substrate structure. Conductive interconnections are deposited to complete the array. The conductive interconnections can be accomplished with a separately prepared interconnection component. The interconnected array is produced using continuous roll-to-roll processing which avoids the need to use the expensive and intricate material removal operations currently taught in the art to achieve electrical interconnections among arrays of photovoltaic cells.

The present invention provides methods of electroplating a film or films onto a top surface of a continuously moving roll-to-roll sheet. In one aspect, the invention includes continuously electroplating a film onto a conductive surface using an electroplating unit as the roll-to-roll sheet moves therethrough, detecting a thickness of the film electroplated onto a portion of the roll-to-roll sheet and generating a thickness signal corresponding thereto. In this aspect, when continuously electroplating, the thickness of the film is adjusted toward a predetermined thickness value using the thickness signal for a subsequent portion of the roll-to-roll sheet that follows the portion of the roll-to-roll sheet.

The invention concerns microcavity plasma devices and arrays with thin foil metal electrodes protected by metal oxide dielectric. Devices of the invention are amenable to mass production techniques, and may, for example, be fabricated by roll to roll processing. Exemplary devices of the invention are flexible. Embodiments of the invention provide for large arrays of microcavity plasma devices that can be made inexpensively. The structure of preferred embodiment microcavity plasma devices of the invention is based upon thin foils of metal that are available or can be produced in arbitrary lengths, such as on rolls. In a device of the invention, a pattern of microcavities is produced in a metal foil. Oxide is subsequently grown on the foil and within the microcavities (where plasma is to be produced) to protect the microcavity and electrically isolate the foil. A second metal foil is also encapsulated with oxide and is bonded to the first encapsulated foil. For preferred embodiment microcavity plasma device arrays of the invention, no particular alignment is necessary during bonding of the two encapsulated foils. A thin glass layer or vacuum packaging, for example, is able to seal the discharge medium into the array.

A process for making a partially transparent photovoltaic cell or a partially transparent photovoltaic module comprising series-connected or parallel-connected photovoltaic cells comprises the step of forming a patterned back electrode(s) by screen printing, jet printing, roll-to-roll processing or depositing through a shadow mask with openings. The pattern of the back electrode is determined at the same time when the back electrode is disposed, such that the complexity and cost of the process can be reduced.

A precursor structure for fabricating light sources, the light sources fabricated therefrom, and the method of fabricating the precursor structure are disclosed. A precursor substrate includes a flexible printed circuit board on which dies are bonded and a separation ridge. The flexible printed circuit board has a bottom heat-conducting layer, an insulating layer, and a circuit layer. The insulating layer and the circuit layer include a plurality of openings that expose the top surface of the heat-conducting layer. The separation ridge extends above the circuit layer and the dies and is configured to prevent contact with the dies and any structures constructed above the dies when the precursor substrate is in contact with a surface positioned over the die and in contact with the separation ridge. The structure is well suited for roll-to-roll processing equipment.

In a flexible substrate for roll-to-roll processing having improved thermal, mechanical, and chemical stabilities, a method of manufacturing the same, and an organic light emitting display apparatus including the same, the flexible substrate for roll-to-roll processing includes a base film formed of an organic material and an inorganic mesh pattern formed of inorganic material. The base film includes a first surface and a second surface opposite to the first surface, the first surface comprising first trenches extending in a first direction and second trenches extending in a second direction. The inorganic mesh pattern buries the first trenches and the second trenches.

Photovoltaic modules comprising back-contact solar cells manufactured using monolithic module assembly techniques comprising a flexible circuit comprising a back sheet and a patterned metallization. The module may comprise busses in electrical contact with the patterned metallization to extract the current. The module may alternatively comprise multilevel metallizations. Interlayer dielectric comprising islands or dots relieves stresses due to thermal mismatch. The use of multiple cord plates enables flexible circuit layouts, thus optimizing the module. The modules preferably comprise a thermoplastic encapsulant and / or hybrid adhesive / solder materials. An ultrathin moisture barrier enables roll-to-roll processing.

In a flexible substrate for roll-to-roll processing having improved thermal, mechanical, and chemical stabilities, a method of manufacturing the same, and an organic light emitting display apparatus including the same, the flexible substrate for roll-to-roll processing includes a base film formed of an organic material and an inorganic mesh pattern formed of inorganic material. The base film includes a first surface and a second surface opposite to the first surface, the first surface comprising first trenches extending in a first direction and second trenches extending in a second direction. The inorganic mesh pattern buries the first trenches and the second trenches.

A deposition method and a system are provided to deposit a CdS buffer layer on a surface of a solar cell absorber layer of a flexible workpiece from a process solution including all chemical components of the CdS buffer layer material. CdS is deposited from the deposition solution while the flexible workpiece is heated and elastically shaped by a heated shaping plate to retain the process solution on the solar cell absorber layer. The flexible workpiece is elastically shaped by pulling a back surface of the flexible workpiece into a cavity area in the heated shaping plate using an attractive force.

The production of liquid crystal displays (LCDS) on plastic substrates is desirable over glass substrates so that the finished product is thinner, lighter, and more robust. Plastic substrates can enable the use of new and different processing techniques which are not possible on glass such as roll-to-roll processing. This invention discusses an advancement which is laser cutting a plastic substrate and display layer. One aspect of the invention is laser cutting and welding together two or more plastic substrates and LCD layer therebetween from a larger sheet or roll of plastic LCDs.

In a method for manufacturing an integral imaging device, a layer of curable adhesive is first applied on a flexible substrate and half cured such that the curable adhesive is solidified but is capable of deforming under external forces. Then the curable adhesive is printed into a lenticular lens having a predetermined shape and size using a roll-to-roll processing device and fully cured such that the curable adhesive is capable of withstanding external forces to hold the predetermined shape and size. Last, a light emitting diode display is applied on the flexible substrate opposite to the lenticular lens such that an image plane of the light emitting diode display coincides with a focal plane of the lenticular lens.

A rolled elliptically polarizing plate that is made by laminating a compensation film 13 having a coated layer made by a coating agent performing a compensation function on the surface of a rolled linear polarizing plate, the compensation film being a rolled film formed by application of a coating agent performing a compensation function to the surface of a transparent substrate, the linear polarizing plate and the compensation film being laminated by means of roll to roll processing by making the respective longitudinal directions approximately in parallel, or the above compensation film being formed by application of a coating agent performing a compensation function to the surface of the rolled linear polarizing plate.

An apparatus for roll-to-roll processing includes a first roller for converting the transmission of a roll of flexible material from a first direction to a second direction substantially orthogonal to the first direction, a second roller spaced apart from the first roller and extending transversely with respect to the first roller for converting the transmission of the roll of flexible material from the second direction to a third direction substantially orthogonal to the first direction and the second direction, and a third roller spaced apart from the second roller and extending perpendicularly with respect to the first roller for converting the transmission of the roll of flexible material from the third direction to a fourth direction, wherein the roll of flexible material includes a first side and a second side, and wherein the first roller, the second roller and the third roller contact the same one of the first side and the second side of the roll of flexible material.

A display device includes a waveguide assembly comprising a waveguide configured to outcouple light out of a major surface of the waveguide to form an image in the eyes of a user. An adaptive lens assembly has a major surface facing the output surface and a waveplate lens and a switchable waveplate assembly. The switchable waveplate assembly includes quarter-wave plates on opposing sides of a switchable liquid crystal layer, and electrodes on the quarter-wave plates in the volume between the quarter-wave plates. The electrodes can selectively establish an electric field and may serve as an alignment structure for molecules of the liquid crystal layer. Portions of the adaptive lens assembly may be manufactured by roll-to-roll processing in which a substrate roll is unwound, and alignment layers and liquid crystal layers are formed on the substrate as it moves towards a second roller, to be wound on that second roller.

An object of the present invention is to provide a method for producing a flexible solar cell module which makes it possible to suitably produce flexible solar cell modules in which a solar cell element and a solar cell encapsulant sheet are well adhered to each other by encapsulating a solar cell by roll-to-roll processing in a continuous manner without the need to perform a crosslinking process and without causing wrinkles and curls. The present invention is a method for producing a flexible solar cell module, including thermocompression bonding of a solar cell encapsulant sheet to at least a light-receiving surface of a solar cell element that includes a flexible substrate and a photoelectric conversion layer on the flexible substrate by pressing the solar cell encapsulant sheet and the solar cell element together between a pair of heating rolls, the solar cell encapsulant sheet including a fluoropolymer sheet and an adhesive layer on the fluoropolymer sheet, the adhesive layer including a silane-modified polyolefin resin.

A rolled elliptically polarizing plate that is made by laminating a compensation film 13 having a coated layer made by a coating agent performing a compensation function on the surface of a rolled linear polarizing plate, the compensation film being a rolled film formed by application of a coating agent performing a compensation function to the surface of a transparent substrate, the linear polarizing plate and the compensation film being laminated by means of roll to roll processing by making the respective longitudinal directions approximately in parallel, or the above compensation film being formed by application of a coating agent performing a compensation function to the surface of the rolled linear polarizing plate.

The invention discloses a high barrier film and a composite film, the high barrier film comprises a polymer substrate and a barrier layer, one side or both sides of the polymer substrate is / are provided with the barrier layer, at least one side outer surface of the high barrier film is provided with a hardened layer, and the hardened layer is light cured resin. The high barrier film capable of improving scratch resistance and puncture resistance is provided and aims at shortcomings of being easy to rupture and scratch in roll-to-roll processing and transportation and handling processes of high barrier films in the prior art, a stable high water and oxygen barrier property can be ensured.

This disclosure features embedded electrooptical displays such as liquid crystal displays and methods of making the same. The displays are embedded in light curable material on one or both sides thereof. Processes for embedding the displays include injection molding and continuous roll-to-roll processing. The light curable material forms a protective covering over the display. Electrical interconnects connected to electrodes of the display can protrude from the protective layer. Once the display is embedded it can resist contact with moisture and mechanical damage. The protective layer can be clear or it can contain additives such as pigments or additives for UV protection. The embedded display with the protective layer may be molded into different shapes during the embedding process or thermoformed after the embedding process into different shapes. This permits the embedded display to be adapted into a variety of different electronic devices such as cell phones, smart phones, MP-3 players, a computer mouse, etc.

A precursor structure for fabricating light sources, the light sources fabricated therefrom, and the method of fabricating the precursor structure are disclosed. A precursor substrate includes a flexible printed circuit board on which dies are bonded and a separation ridge. The flexible printed circuit board has a bottom heat-conducting layer, an insulating layer, and a circuit layer. The insulating layer and the circuit layer include a plurality of openings that expose the top surface of the heat-conducting layer. The separation ridge extends above the circuit layer and the dies and is configured to prevent contact with the dies and any structures constructed above the dies when the precursor substrate is in contact with a surface positioned over the die and in contact with the separation ridge. The structure is well suited for roll-to-roll processing equipment.

A process for making a partially transparent photovoltaic cell or a partially transparent photovoltaic module comprising series-connected or parallel-connected photovoltaic cells comprises the step of forming a patterned back electrode(s) by screen printing, jet printing, roll-to-roll processing or depositing through a shadow mask with openings. The pattern of the back electrode is determined at the same time when the back electrode is disposed, such that the complexity and cost of the process can be reduced.

An object of the present invention is to provide a solar cell encapsulant sheet which makes it possible to suitably produce flexible solar cell modules in which the solar cell encapsulant sheet is well adhered to a solar cell element by encapsulating a solar cell element by roll-to-roll processing in a continuous manner without the need to perform a crosslinking process and without causing wrinkles and curls. The present invention provides a solar cell encapsulant sheet including a fluoropolymer sheet and an adhesive layer that includes a maleic anhydride-modified olefin resin on the fluoropolymer sheet, the maleic anhydride-modified olefin resin being a resin in which an α-olefin-ethylene copolymer that includes 1 to 25% by weight of α-olefin units is graft-modified with maleic anhydride, and a total amount of maleic anhydride being 0.1 to 3% by weight.

The invention concerns microcavity plasma devices and arrays with thin foil metal electrodes protected by metal oxide dielectric. Devices of the invention are amenable to mass production techniques, and may, for example, be fabricated by roll to roll processing. Exemplary devices of the invention are flexible. Embodiments of the invention provide for large arrays of microcavity plasma devices that can be made inexpensively. The structure of preferred embodiment microcavity plasma devices of the invention is based upon thin foils of metal that are available or can be produced in arbitrary lengths, such as on rolls. In a device of the invention, a pattern of microcavities is produced in a metal foil. Oxide is subsequently grown on the foil and within the microcavities (where plasma is to be produced) to protect the microcavity and electrically isolate the foil. A second metal foil is also encapsulated with oxide and is bonded to the first encapsulated foil. For preferred embodiment microcavity plasma device arrays of the invention, no particular alignment is necessary during bonding of the two encapsulated foils. A thin glass layer or vacuum packaging, for example, is able to seal the discharge medium into the array.

A hermetically sealed electronic device and method of fabrication are provided. A base layer of a wafer is created using a substrate formed from ultra-thin glass or ceramic using panel or roll to roll processing. One or more layers are bonded to the base layer. The wafer is singulated into a plurality of electronic devices having a top surface and a plurality of sides. A hermetic sealant is applied to each electronic device to completely encase the top surface and the sides while bonding to the base layer. At least one of the layers is a metallization layer formed by metal deposition. Full metallization may be applied over the entire wafer and a pattern subsequently transferred to the full metallization by one of laser and chemical etching. The electronic device may further include at least one electronic component attached to one of the layers and encased by the hermetic sealant.

An input device is manufactured from a roll of a single-layer flexible transparent base sheet having a first surface and a second surface by forming a transparent electrode pattern and a wiring layer on the first surface. The transparent electrode pattern is disposed in a transparent input region, and the wiring layer extends from an end of the transparent electrode pattern into a decorative region surrounding the transparent input region. A decorative layer pattern is formed on the second surface in the decorative region, while conveying the transparent base sheet through a roll-to-roll processing. The transparent base sheet having the transparent electrode pattern and the decorative layer pattern is divided into individual units. A transparent panel having an operation surface is bonded to the second surface of each of the individual units with an optically clear adhesive layer interposed therebetween.

Provided is a method for producing a metal-clad laminate of a thermoplastic liquid crystal polymer film (TLCP film) and a metal sheet(s) bonded to at least one surface of the film using roll-to-roll processing. The metal sheet has a surface with a ten-point average roughness (Rz) of 5.0 μm or less to be bonded to the TLCP film. The method includes preparing the laminate, dry-treating the laminate by subjecting the laminate passed through a dry zone satisfying the following conditions (1) and (2):(1) a drying temperature of lower than the melting point of the TLCP film,(2) for a drying period of 10 seconds or longer, andheat-treating the dried laminate by subjecting the laminate passed through a heating zone on a temperature condition of not lower than the melting point of the TLCP film successively after the dry treatment.

Processes for economical large scale commercial production of blocks of quantum well particles, platelets, or continuous sheets of material imparting minimal or essentially no parasitic substrate loss in quantum well devices such as thermo-electric generators in which the blocks are embodied involve roll to roll processing, i.e., deposition and crystallization of alternating layers of quantum well materials, on an elongate and continuous base layer of appreciable width. Blocks of quantum well materials having no attached base layer are produced on decomposable or release treated base layers.