Method and system for correcting web deformation during a roll-to-roll process

A system for correcting web deformation during a roll-to-roll process comprising:

• means for initiating a roll-to-roll process involving a flexible web substrate;
• means for detecting web deformation in the flexible web substrate during the roll-to-roll process;
• and
• means for utilizing controllable mechanical components wherein the controllable mechanical components comprise spherical nips to dynamically correct the flexible web substrate based on the detected web deformation.

A roll-to-roll processing system comprising:

• a web rolling mechanism;
• a flexible web substrate coupled to the web rolling mechanism;
• a plurality of sensors configured to dynamically detect deformation in the flexible web substrate;
• at least one controllable mechanical component coupled to the flexible web substrate wherein the at least one controllable mechanical component comprises a spherical nip;
• and
• a computer system coupled to the plurality of sensors and the at least one controllable mechanical component wherein the computer system includes logic for detecting web deformation in the flexible web substrate;
• and
• dynamically correcting the flexible web substrate based on the detected deformation.

A computer program product for correcting web deformation during a roll-to-roll process wherein the computer program product includes a computer usable medium having computer readable program means for causing a computer to perform the steps of:

• initiating a roll-to-roll process involving a flexible web substrate;
• detecting web deformation in the flexible web substrate during the roll-to-roll process;
• and
• dynamically correcting the flexible web substrate based on the detected web deformation wherein dynamically correcting the flexible web substrate comprises utilizing controllable mechanical components to correct the flexible web substrate based on the detected web deformation wherein the controllable mechanical components comprise spherical nips.

A method for correcting web deformation during a roll-to-roll process comprising:

• utilizing optical markings on a flexible web substrate to detect the deformation in the flexible substrate;
• comparing the detected deformation with a desired deformation;
• generating an error signal based on the comparison;
• and
• generating a correction signal to be utilized to dynamically correct the flexible web substrate;
• and
• dynamically correcting the flexible web substrate based on the correction signal wherein dynamically correcting the flexible web substrate comprises utilizing controllable mechanical components to correct the flexible web substrate based on the detected web deformation wherein the controllable mechanical components comprise spherical nips.

A method for correcting web deformation during a roll-to-roll process comprising:

• initiating a roll-to-roll process involving a flexible web substrate;
• detecting web deformation in the flexible web substrate during the roll-to-roll process;
• and
• utilizing controllable mechanical components to connect the flexible web substrate based on the detected web deformation wherein the controllable mechanical components include spherical nips wherein each spherical nip includes a spring loaded counter roller.