Methods of and apparatus for making a flexible composite having reservoirs and capillaries

Abstract

A method of manufacturing a flexible composite panel having a plurality of reservoirs connected by at least one capillary includes forming a capillary assembly by winding a flexible, deformable capillary base web partially around a rotating cylinder that has a plurality of recessed features formed therein; drawing the capillary base web into the recessed features to form the capillaries in the capillary base web; filling the capillaries; and laminating a capillary barrier web over the capillary base web. A flexible reservoir assembly is formed by cutting the perimeter of the at least two reservoirs and associated catchments into a flexible reservoir web; removing the waste cut interiors of the reservoirs and the catchments from the reservoir web; securing the reservoir web to a base layer; overfilling each reservoir; and laminating the capillary assembly over the reservoir assembly, driving excess filler from the reservoirs into the catchments.

1 . A method of forming a flexible capillary assembly having a set of at least one filled capillary, the method comprising:
 winding a flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to a set of capillaries;   connecting the recessed features underlying the capillary base web to a source of reduced pressure to draw the capillary base web into the recessed features and form the set of capillaries therein;   applying a fill material to the surface of the capillary base web to fill the set of capillaries; and   laminating a flexible capillary barrier web over the capillary base web to close the set of capillaries.   
     
     
         2 . The method according to  claim 1 , wherein the step of applying a fill material uses a chambered doctor blade system, with a central wet zone of the fill material and entrance and exit blades, to apply the fill material to the set of capillaries passing below the central wet zone of the chambered doctor blade system, as the cylinder rotates. 
     
     
         3 . The method according to  claim 1 , wherein the step of laminating the capillary barrier web over the capillary base web comprises applying the capillary barrier web to the carrier base web, while the capillary base web is on the rotating cylinder, using a lamination roller. 
     
     
         4 . The method according to  claim 3 , wherein the capillary barrier web comprises a barrier layer and a peelable support layer, and further comprising the step of forming vias in the barrier layer, which provide access to the capillaries when the peelable support layer is removed. 
     
     
         5 . A method of forming a flexible capillary assembly having a set of at least one filled capillary, the method comprising:
 winding a first flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to a set of capillaries;   selectively connecting the recessed features underlying the capillary base web to a source of reduced pressure to draw the capillary base web into the recessed features and form a set of capillaries therein; and   selectively disconnecting the recessed features exposed to the atmosphere from the source of reduced pressure.   
     
     
         6 . The method according to  claim 5 , wherein the capillary base web is applied to the surface of the rotating cylinder with a first lay-on roller, and wherein the capillary base web is removed from the rotating cylinder with a second lay-on roller. 
     
     
         7 . The method according to  claim 6 , wherein the recessed features in the surface of the cylinder between the first lay-on roller, where the capillary base web is applied and the second lay-on roller where the capillary base web is removed are selectively connected to a source of reduced pressure, and wherein the recessed features in the surface of the cylinder between the second lay-on roller where the capillary base web is removed and the first lay-on roller, where the capillary base web is applied are selectively disconnected from the source of reduced pressure. 
     
     
         8 . A tool for forming a flexible capillary assembly having at least one set of at least one filled capillary, the tool comprising:
 a rotatably mounted cylinder having a plurality of circumferentially spaced zones;   at least one set of recessed features formed in the surface of at least some of the zones, each set corresponding to a set of capillaries, and each set having a port therein; and   each of the zones having a manifold communicating with the ports of each of the sets of recessed features in the zone, the manifold being selectively connectable to a source of reduced pressure to selectively connect the sets of recessed features in the zone to the source of reduced pressure.   
     
     
         9 . The tool according to  claim 8 , wherein the cylinder comprises a core and a sleeve, removeably mounted over the core, and wherein the sets of recessed features are formed in the sleeve. 
     
     
         10 . The tool according to  claim 9 , wherein at least a portion of the manifold of each zone is in the core, and further comprising at least one seal between the core and the sleeve to provide sealed communication between the manifold and the port of each set of recessed features. 
     
     
         11 . The tool according to  claim 10 , wherein the at least one seal between the core and the sleeve is pressurizable. 
     
     
         12 . The tool according to  claim 10 , wherein the seal comprises an o-ring surrounding an opening of the manifold in the core, which encompasses the port of at least one set of recessed features. 
     
     
         13 . The tool according to  claim 12 , wherein the o-ring of each seal is seated in a seat formed in the surface of the core, and further comprising a passage for selectively pressurizing the seat to urge the o-ring into engagement with the sleeve installed over the core. 
     
     
         14 . The tool according to  claim 8 , further comprising mating portions on the core and the sleeve to ensure that the sleeve is properly oriented with respect to the core. 
     
     
         15 . A method of forming a flexible reservoir assembly having a set of at least one filled reservoir, the method comprising:
 cutting the perimeter of the set of at least one reservoir into a flexible reservoir web secured to a peelable support layer;   removing the support layer and the waste cut interiors of the reservoirs of the set of reservoirs from the reservoir web;   securing the reservoir web to a base layer;   overfilling each reservoir in the set by depositing a plurality of layers of filling material into each reservoir; and   laminating a reservoir barrier layer over the overfilled reservoirs.   
     
     
         16 .- 35 . (canceled) 
     
     
         36 . A method of manufacturing a flexible composite panel having a set of plurality of reservoirs connected by a set of at least one capillary, the method comprising:
 laminating a flexible capillary assembly, that has at least one via communicating with the capillary, over a reservoir assembly, having at least one reservoir therein so that the contents of a reservoir and the contents of a capillary can react through a via, and crimping the capillary adjacent the via to restrict further interaction between the contents of the reservoir and the contents of the capillary.   
     
     
         37 . The method according to  claim 36 , wherein the step of crimping the capillary comprises applying a removable structure to temporarily crimp the capillary.