Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing

Abstract

A roll-to-roll manufacturing system performs printing and coating on webs to mass-produce large-area functional films. The functional film of a multilayered structure is composed of layers with different components for performance improvement. The roll-to-roll system is capable of controlling the geometries of the coating and printing layers using process variables. However, research on geometric control using process variables is limited to single-layer structures only. This study entails the development of a method to proactively control the geometry of the upper coated layer by using the lower-layer coating process variable in the manufacture of a double-coated layer. The correlation between the lower-layer coating process variable and upper coated layer geometry was examined by analyzing the lower-layer surface roughness and spreadability of the upper-layer coating ink. The correlation analysis results demonstrate that tension was the dominant variable in the upper coated layer surface roughness. Additionally, this study found that adjusting the process variable of the lower-layer coating in a double-layered coating process could improve the surface roughness of the upper coating layer by up to 14.9%.

Enhancing Diagnosis of Rotating Elements in Roll-to-Roll Manufacturing Systems through Feature Selection Approach Considering Overlapping Data Density and Distance Analysis

“…In this study, only SVM was used to verify the performance, and no other machine learning or deep learning techniques were used. In addition, since the data for the eccentricity experiment were collected in only one experimental setting, the data for various R2R system conditions [ 69 , 70 , 71 ] were not available, so it was not possible to verify the performance trend of the learning model according to the roll-to-roll system setup condition. Therefore, future research could use various machine learning and deep learning methods to achieve additional diagnostic performance from the technique and identify the impacts of different R2R system setup conditions like web materials, sensor types, imbalanced conditions, which could make significant contributions in computational domains and furthermore the physical domain.…”

Control of Meniscus Formation Using an Electrohydrodynamics Module in Roll-to-Roll Systems for the Stable Coating of Functional Layers

“…Additionally, as shown in Figure 10 c, the elastic modulus of the material was 3.19 , and the yield strength was 109.7 , as confirmed by the stress–strain curve. The tension applied to the PET film in the R2R system ranged from 10% to 25% of the material’s yield strength [ 51 , 52 ]. Considering the yield strength of the PET used in the experiment, a tension of 2 kgf was applied in this study.…”

Acidochromic Free-Standing Multilayered Chitosan-Pyranoflavylium/Alginate Membranes toward Food Smart Packaging Applications

“…Therefore, an azide-containing Pyflav dye (PyFlav-N 3 ) was first designed and synthesized and further functionalized to an alkyne-modified chitosan (CHT-Alk) via copper-catalyzed azide–alkyne cycloaddition reaction (CuAAC). Afterward, the fabrication of acidochromic free-standing (FS) membranes composed by alginate and chitosan-pyranoflavylium conjugate (CHT-PyFlav) was performed through bottom-up electrostatic-driven layer-by-layer (LbL) supramolecular assembly technology. , …”

“…Afterward, the fabrication of acidochromic free-standing (FS) membranes composed by alginate and chitosan-pyranoflavylium conjugate (CHT-PyFlav) was performed through bottom-up electrostatic-driven layer-by-layer (LbL) supramolecular assembly technology. 27,28 In addition to producing functional membranes and thinfilms with precise control over their thickness and composition, LbL assembly technology has proven to be an easy, affordable, and remarkably versatile technique for coating surfaces and creating a wide range of multifunctional layered structures with customizable compositions, architectures, properties, and functionalities. The deposition process can be influenced by different types of interactions, including electrostatic ones between charged polymers, hydrogen bonding, hydrophobic forces, and van der Waals forces.…”

“…Afterward, the fabrication of acidochromic free-standing (FS) membranes composed by alginate and chitosan-pyranoflavylium conjugate (CHT-PyFlav) was performed through bottom-up electrostatic-driven layer-by-layer (LbL) supramolecular assembly technology. 27 , 28 …”