Apparatus and method for patterning a film

• US 5,216,543 A
• Filed: 03/04/1987
• Issued: 06/01/1993
• Est. Priority Date: 03/04/1987
• Status: Expired due to Fees

• Current Assignee: 3M Company
• Original Assignee: 3M Company
• Inventors: Calhoun, Clyde D.
• Primary Examiner(s): Arnold, Bruce Y.
• Assistant Examiner(s): SHAFER, RICKY D
• Application Number:
  US07/021,458
• Time in Patent Office: 2,281 Days
• Field of Search: 219/121.69, 219/121.67, 428/601, 428/626, 428/46, 430/946, 430/945, 430/4, 430/5, 430/9, 430/13, 430/14, 430/270, 430/271, 430/311, 430/321, 430/495, 430/501, 346/77 E, 346/151, 136/246, 136/259, 136/243, 136/244, 136/249, 283/109, 283/904
• US Class Current: 359/619
• CPC Class Codes: B23K 2101/40 Semiconductor devices
• CPC Class Codes: B23K 2103/08 Non-ferrous metals or alloys
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B23K 2103/172 wherein at least one of the layers is non-metallic
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/0006 taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/067 Dividing the beam into multiple beams, e.g. multifocusing
• CPC Class Codes: B23K 26/0676 into dependently operating sub-beams, e.g. an array of spots with fixed spatial relationship or for performing simultaneously identical operations
• CPC Class Codes: G02B 3/005 arranged along a single direction only, e.g. lenticular sheets G02B3/0043 takes precedence
• CPC Class Codes: H01L 31/0543 comprising light concentrating means of the refractive type, e.g. lenses
• CPC Class Codes: Y02E 10/52 PV systems with concentrators
• CPC Class Codes: Y10S 430/147 Lenticular
• CPC Class Codes: Y10T 428/24917 including metal layer
• CPC Class Codes: Y10T 428/2804 Next to metal
• CPC Class Codes: Y10T 428/2848 Three or more layers

Abstract

The present invention relates to an apparatus and method for patterning areas of a radiation absorbent film material. In the preferred embodiment, the film material is at least partially electrically conductive. The radiation is focused onto the film by a lenticular lens having a plurality of optically active elements to provide a radiation pattern on the film and remove or displace portions of the film to form a corresponding pattern, preferably a conductive pattern. The film may have one or more layers or regions, but at least one region must be radiation absorbent in order to allow the formation of patterns in the film in accordance with the present invention. The areas of the film affected by the phenomenon of radiation absorption are non-conductive voids which may separate the film into a plurality of conductive grid lines whereby the film is useful with a conductive lens film to increase the apparent efficiency of a photovoltaic cell.

Claims

1. A patterned sheet comprising a radiation absorbent layer containing multiple discontinuities extending transversely through the plane of said layer and wherein said radiation absorbent layer is confined between adjacent, radiation transparent layers, said radiation absorbent layer comprising both absorbent and reflective materials arranged so that the absorbent material receives incident radiation wherein at least one of said radiation transparent layers is a lenticular lens having fields of focus which lie at least partially within the plane of said absorbent layer and wherein the fields of focus of said lens correspond to the area of discontinuity of said absorbent layer.

2. A photovoltaic device comprising

a) a conductive, radiation absorbent layer containing a pattern of multiple discontinuities extending transversely through the plane of said layer, said layer supported by a radiation transparent layer adjacent one major surface, said radiation transparent layer comprising a lenticular lens means having fields of focus which lie at least partially within the plane of said absorbent layer and wherein said fields of focus correspond to the areas of discontinuity of said absorbent layer,

b) a conductive, pressure sensitive adhesive layer adhered to at least a portion of the major surface of said radiation absorbent layer opposite said radiation transparent layer, and

c) a photovoltaic cell having its active surface electrically and physically connected to said conductive, radiation absorbent layer by said conductive adhesive.

3. A conductive sheet, comprising:

a) a conductive, radiation absorbent layer containing a pattern of multiple discontinuities extending transversely through the plane of said absorbent layer;

b) a radiation transparent layer adjacent one major surface of said absorbent layer for supporting said absorbent layer;

wherein said radiation transparent layer comprises a lenticular lens means having fields of focus which lie at least partially within the plane of said absorbent layer and wherein the fields of focus of said lens means correspond to the areas of discontinuity of said absorbent layer; and

c) a conductive, pressure sensitive adhesive layer adhered to at least a portion of the surface of said absorbent layer opposite said radiation transparent layer.

4. A method for patterning a radiation absorbent film comprising the following steps:

a) directing radiation from a radiation source onto a lenticular lens,

b) focusing said radiation onto a radiation absorbent film, said film comprising a radiation absorbent region overlying a radiation reflective region, said radiation absorbent region capable of absorbing sufficient radiant energy to raise the temperature of the adjacent reflective region to a point where local discontinuities occur, wherein said film is in register with, but separable from said lens, said radiation forming a pattern on said film,

c) disrupting said film in the radiation-incident areas as a result of absorption of the radiation by said film, and

d) moving said lens and said film relative to one another.