Method of producing a component of a device, and the resulting components and devices

Abstract

The present method comprises providing a flexible web substrate (e.g., polymeric flexible web substrates) that forms at least part of a component of a device, coating so as to wet-out on and cover all or a substantial portion of a major surface on one side or both sides of the flexible web substrate with flowable polymeric material, while the flexible web substrate is moving in a down-web direction, and solidifying the polymeric material so as to form one cleaning layer on the major surface of one side or both sides of the flexible web substrate. The present invention can be utilized in a continuous in-line manufacturing process. In applications of the present invention where the flexible web substrate will not form a component of a device, the present invention broadly provides a method for cleaning particles from a flexible web of indefinite length. Each cleaning layer forms a substantially adhesive bond to the major surface that is readily removable without damaging or leaving a substantial residue of cleaning layer material on the major surface. A substantial number of the particles that were on this major surface are captured by and removable with the cleaning layer.

What is claimed is: 
     
         1 . A method of cleaning particles from a major surface of a flexible web substrate of indefinite length, said method comprising:
 providing a flexible web substrate having opposite sides, a major surface on each side and an indefinite length;   coating so as to wet-out on and cover a major surface on one side or both sides of the flexible web substrate with polymeric material, while the flexible web substrate is moving in a down-web direction; and   solidifying the polymeric material so as to form one cleaning layer on the major surface of one side or both sides of the flexible web substrate,   
       wherein each cleaning layer forms a substantially adhesive bond to, is readily removable from without damaging or leaving a substantial residue of cleaning layer material on, and captures a substantial number of particles disposed on, the major surface on which it is formed, and the removal of each cleaning layer reveals one clean surface. 
     
     
         2 . A flexible web comprising:
 a flexible web substrate having opposite sides, a first major surface on one side and a second major surface on another side and an indefinite length; and   a first cleaning layer of solidified polymeric material coated onto, and in direct contact with, said first major surface,   wherein said first cleaning layer forms a substantially adhesive bond to said first major surface, is readily removable from said first major surface without damaging or leaving a substantial residue of cleaning layer material on said first major surface, and captures a substantial number of particles that were disposed on said first major surface before said first cleaning layer was coated thereon, and upon the removal of said first cleaning layer, said first major surface becomes a first clean surface that is free of said substantial number of particles.   
     
     
         3 . The flexible web according to  claim 2 , wherein said flexible web substrate comprises a polymeric web substrate. 
     
     
         4 . The flexible web according to  claim 2 , wherein said flexible web substrate comprises a first metallic layer having a first metallic surface defining said first major surface, and said metallic layer is substantially free of pinhole defects. 
     
     
         5 . The flexible web according to  claim 2 , wherein said flexible web substrate comprises a first polymeric planarization coating having a first planarized surface defining said first major surface. 
     
     
         6 . The flexible web according to  claim 2 , wherein said flexible web substrate comprises a first polymeric planarization coating having a first planarized surface metalized with a first metallic coating having a first metallic surface, said first metallic surface defining said first major surface, and said first metallic layer being substantially free of pinhole defects. 
     
     
         7 . The flexible web according to  claim 2 , wherein said first cleaning layer is removed from said first major surface, and said first clean surface is substantially free of particles that are of a size equal to or larger than about 3 micrometers in diameter. 
     
     
         8 . The flexible web according to  claim 2 , wherein said first cleaning layer is removed from said first major surface, and said first clean surface is substantially free of ultra-fine particles having a diameter of at least about 0.1 micrometers and larger particles. 
     
     
         9 . The flexible web according to  claim 7 , wherein said first cleaning layer captures at least about 25 percent of the particles that were on said first major surface before being coated with said first cleaning layer. 
     
     
         10 . The flexible web according to  claim 7 , wherein said first cleaning layer captures at least about 50 percent of the particles that were on said first major surface before being coated with said first cleaning layer. 
     
     
         11 . The flexible web according to  claim 7 , wherein said first cleaning layer captures at least about 99.0 percent of the particles that were on said first major surface before being coated with said first cleaning layer. 
     
     
         12 . The flexible web according to  claim 2 , further comprising:
 a second cleaning layer of solidified polymeric material coated onto, and in direct contact with, said second major surface,   wherein said second cleaning layer forms a substantially adhesive bond to said second major surface, is readily removable from said second major surface without damaging or leaving a substantial residue of cleaning layer material on said second major surface, and captures a substantial number of particles that were disposed on said second major surface before said second cleaning layer was coated thereon, and upon the removal of said second cleaning layer, said second major surface becomes a second clean surface that is free of said substantial number of particles   
     
     
         13 . The flexible web according to  claim 12 , wherein said flexible web substrate comprises a second metallic layer having a second metallic surface defining said second major surface, and said second metallic layer is substantially free of pinhole defects. 
     
     
         14 . The flexible web according to  claim 12 , wherein said flexible web substrate comprises a second polymeric planarization coating having a second planarized surface defining said second major surface. 
     
     
         15 . The flexible web according to  claim 12 , wherein said flexible web substrate comprises a second polymeric planarization coating having a second planarized surface metalized with a second metallic coating having a second metallic surface, said second metallic surface defining said second major surface, and said second metallic layer being substantially free of pinhole defects. 
     
     
         16 . The flexible web according to  claim 12 , wherein said second cleaning layer is removed from said second major surface, and said second clean surface is substantially free of particles that are of a size equal to or larger than about 3 micrometers in diameter. 
     
     
         17 . The flexible web according to  claim 12 , wherein said second cleaning layer is removed from said second major surface, and said second clean surface is substantially free of ultra-fine particles having a diameter of at least about 0.1 micrometers and larger particles. 
     
     
         18 . The flexible web according to  claim 16 , wherein said second cleaning layer captures at least about 25 percent of the particles that were on said second major surface before being coated with said second cleaning layer. 
     
     
         19 . The flexible web according to  claim 16 , wherein said second cleaning layer captures at least about 50 percent of the particles that were on said second major surface before being coated with said second cleaning layer. 
     
     
         20 . The flexible web according to  claim 16 , wherein said second cleaning layer captures at least about 99.0 percent of the particles that were on said second major surface before being coated with said second cleaning layer. 
     
     
         21 . The flexible web according to  claim 2 , further comprising an overcoat applied onto a side of said first cleaning layer opposite said flexible web substrate. 
     
     
         22 . The flexible web according to  claim 21 , wherein said overcoat comprises an adhesive layer. 
     
     
         23 . The flexible web according to  claim 22 , wherein said flexible web is wound into a roll, with said adhesive layer being adhered to the other side of said flexible web substrate such that, when said roll is unwound, said adhesive layer remains bonded to the other side of said flexible web substrate and to said first cleaning layer, and said first cleaning layer is removed from the first major surface of said flexible web substrate. 
     
     
         24 . The flexible web according to  claim 2 , further comprising a pressure sensitive adhesive layer adhered to the other side of said flexible web substrate, and said first cleaning layer has an exposed surface comprising a release material, wherein said adhesive layer adheres to and is readily releasable from said exposed surface, when said flexible web is wound into a roll and unwound. 
     
     
         25 . The flexible web according to  claim 7 , wherein each cleaning layer is removed in one piece. 
     
     
         26 . The flexible web according to  claim 2 , wherein the polymeric material of each cleaning layer comprises a thermoplastic polymeric material. 
     
     
         27 . The flexible web according to  claim 2 , wherein the polymeric material of said each cleaning layer comprises a thermosetting polymeric material that is not cross-linked. 
     
     
         28 . The flexible web according to  claim 2 , wherein the polymeric material of each cleaning layer comprises a thermosetting polymeric material that is only slightly cross-linked. 
     
     
         29 . A flexible component of an electronic device, said component comprising the flexible web according to  claim 2 , wherein each said clean surface satisfies the minimum cleanliness requirements of the electronic device. 
     
     
         30 . An electronic device comprising said flexible component according to  claim 29 . 
     
     
         31 . The electronic device according to  claim 30 , wherein said device is selected from the group consisting of an electroluminescent (EL) device, a photovoltaic cell, a semiconductor device, an organic field effect transistor, a thin film transistor, and an integrated circuit. 
     
     
         32 . The flexible web of  claim 2  wherein the first major surface comprises a structured surface. 
     
     
         33 . The flexible web of  claim 32  wherein the structured surface is micro-replicated or embossed. 
     
     
         34 . The flexible web of  claim 2  wherein the cleaning layer comprises a thermosetting polymeric material curable by radiation. 
     
     
         35 . The flexible web of  claim 2  wherein the cleaning layer, after removal, is useable as a polymeric film material.