Patent ID: 8535041
Filing Date: 2013-09-17
Classification: A01J,B82Y,G02F,G03F

Abstract:
1. A system for forming addressable three-dimensional elements on a flexible substrate, the system comprising: a first flexible substrate including a first desired pattern of conductive material; a second flexible substrate configured to hold a second desired pattern, wherein the second desired pattern is a three-dimensional (3D) pattern; a roll-to-roll system including (i) a first rotatable supply spool configured to hold a first substrate, (ii) a second rotatable supply spool configured to hold a second substrate, (iii) a first rotatable take-up spool configured to hold the first substrate, and (iv) a second rotatable uptake spool configured to hold the second substrate, wherein the roll-to-roll system is configured to transfer the first desired pattern of conductive material from the first flexible substrate to the second flexible pattern of the second flexible substrate; and an embossing tool having surface protrusions corresponding to a desired three-dimensional pattern, wherein the embossing tool is configured to impart the desired three-dimensional pattern to a layer of the second flexible substrate to form the second desired pattern, wherein the embossing tool comprises a rotatable drum, wherein the drum includes a replication tool including (i) a sleeve having an outer durable surface defined by a first diameter and an inner surface defined by a second diameter, the inner surface forming a bore, wherein the sleeve has a height along a longitudinal axis perpendicular to the inner and outer diameters; (ii) a relief pattern disposed on the outer surface of the sleeve, wherein the relief pattern includes a seamless three-dimensional pattern; and (iii) a mounting fixture for supporting the sleeve in rotation as the outer surface of the sleeve is pressed against a substrate; a means for removal of a desired amount of material from selected areas of the three-dimensional pattern of the second desired pattern; and are registration means for registering the first desired pattern in specific geometric relationship with the second desire pattern.