A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Multi-layer deformable composite construction for use in a subterranean well

Systems, methods, and apparatus are disclosed for making patterning tools from one or more discrete elements. Such tools can have one or more “seams” or joints where the individual elements abut which can limit the tools' performance and utility in roll-to-roll manufacturing. Methods are described herein for producing “near-seamless” tools, that is, tools having seams that exhibit minimum disruption of the tool pattern and thus improved material produced by such tools. The patterning tools can be cylindrical and/or closed in shape.

Formation of pattern replicating tools

Systems and methods are disclosed by which patterns of various materials can be formed on flexible substrates by a continuous roll-to-roll manufacturing process. The patterns may include metallic, transparent conductive, or non-metallic elements with lateral dimensions including in the range from below 100 nanometers to millimeters and with thickness dimensions including the range from tens of Angstroms to greater than 10,000 Angstroms. The substrate may be any material capable of sufficient flexibility for compatibility with roll-based processing equipment, including polymeric films, metallic foils, and thin glass, with polymeric films representing a particularly broad field of application. Methods may include the continuous roll-to-roll formation of a temporary polymeric structure with selected areas open to the underlying substrate, the continuous addition or subtraction of constituent materials, and the continuous removal, where necessary, of the polymeric structure and any excess material.

Roll-to-roll patterning of transparent and metallic layers

An improved method of manufacturing a photosensitive printing element that minimizes relief variation and improves image fidelity. The method involves a step of pre-curing the first (floor layer) of photocurable material prior to depositing an additional layer or layers of photocurable material that may be imaged and developed to produce a desired relief image on the surface of the photosensitive printing element. The photosensitive printing element is then thermally developed by contacting the photosensitive printing element with at least one roll that is capable of moving over at least a portion of the imaged surface of the flexographic printing element to remove the softened or melted non-crosslinked photopolymer. Non-crosslinked photopolymer on the imaged and exposed surface of the flexographic printing element can be softened or melted by positioning a heater adjacent to the imaged surface of the flexographic printing element and/or heating the at least one roll that contactable with the imaged surface of the flexographic printing element.

Method for thermally processing photosensitive printing sleeves

A seamless printing sleeve comprising a hollow cylindrical base and a seamless imageable surface as its outermost layer is described. The imageable surface acts as an integral flexographic printing surface. Preferably the printing sleeve comprises an intermediate photopolymer or resilient polymer layer between the outer surface of the base and the imageable surface. Also, preferably the base is uniformly transparent or translucent to actinic radiation.

Printing sleeve with an integrated printing surface

A sleeve for a print cylinder comprising a fiber reinforced, thin-walled material and having a seamless surface ready to be covered with a surface material. The sleeve may be used in flexographic printing, either as a support for photo-polymerized printing plates or rubber layers. The sleeve has the advantages of having low manufacturing cost and providing the necessary heat resistance to withstand rubber vulcanization temperatures. The sleeve is also airtight, and remains properly positioned during printing operations.

Thin-walled reinforced sleeve with integral compressible layer

A method of making a photopolymer sleeve blank (10) for use in flexographic printing is provided which includes providing a base sleeve (12), applying a cushion layer (14) over the base sleeve (12) which is substantially transparent to curing radiation, applying an optional barrier layer (16) over the cushion layer (14), and applying a photopolymer layer (18) over the barrier or cushion layer. The inner surface of the base sleeve is then exposed to curing radiation such that the radiation penetrates the sleeve and cushion layer to substantially cure a portion of the thickness of the photopolymer layer.

Method of making a photopolymer sleeve blank having an integral uv transparent cushion layer for flexographic printing

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Thin-walled reinforced sleeve with integral compressible layer

Method of making a photopolymer sleeve blank having an integral uv transparent cushion layer for flexographic printing