Optimal design and fabrication of a light guide film with roll to roll process

Wang, Min-Wen; Lin, Wenqing; Lee, Ming-Hsiao

doi:10.1007/s00542-013-1900-2

Cited by 9 publications

(3 citation statements)

References 13 publications

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“…78,79,81,82,101,102 Unlike traditional methods using a flat roll, gravure printing (also called imprinting) has attracted enormous interest in the industry due to their precise, small area capability, and high resolution. 84,103,104 Using a combination of gravure printing along with selective etching process, Ok et al successfully printed plasmonic infrared filters as shown in Figure 12. 87 Gravure printing relies largely on the surface tension of a solution ink in the engraved cavities of the gravure roll.…”

Section: Roll-to-roll Printing (Rtr)mentioning

confidence: 99%

Advances in 2D/3D Printing of Functional Nanomaterials and Their Applications

Choi

Das

Theodore³

et al. 2015

ECS J. Solid State Sci. Technol.

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Advanced printing techniques include innovative and/or integrated processes that are used to produce an object with enhanced functionality and with a wide range of applications. This is done by realizing printing of functional materials such as ink, paste, polymer, ceramic powder, and organic materials. Unlike conventional manufacturing methods, a new technique is needed to manipulate small objects to fabricate desired parts, as materials are scaled down to the nanometer range. In this regard, the traditional subtractive production has been changed to a bottom-up approach as device structures have changed to multilayer structures which contain several functional nanomaterials. A powder is used to fabricate an object with a desired geometry. This reduces the material loss due to the bottom-up nature of the process. In this article, we review the current state of knowledge for advanced manufacturing using two methods, 3D printing and roll-to-roll manufacturing. 3D printers developed in the early 1980s1 has created a revolution in research and development and teaching laboratories due to a substantial price drop after 2010 and an easy software called plugplay that allows most people to use it without extensive technical help.2,3 Based on economic analysis, the market for 3D printers is growing significantly. This is driven by a number of sectors including aerospace, automotive, and medical/dental and the market was worth several billions in 2013. During the last decade, the business has increased exponentially due to the 3D printing technology enabling the fabrication of complex objects with enhanced functionalities and improved material properties.4,5 Desktop 3D printers were targeted primarily at hobbyists and consumers who are not in industry. However, the need of industry-level 3D printers has attracted a lot of attention from researchers and scientists in the fields of biotechnology, automotive, architecture, electrical, electronic, photonic, optical, and sensor engineering.6-10 Printers' resolution is dropping under 100 micrometers (250 dot per inch (DPI)) with a typical layer thickness of 100 micrometers. The primary advantage of a 3D printer is its ability to create any shape in the micrometer range up to several meter range depending on the supporting holder.Over the past few years a rapid growth in the 3D printing industry has been observed as evidenced by the enormous numbers of articles published in scientific journals and patents filed as illustrated in Figure 1. Advances in the 3D printing technology will also lead to significant price drop, owing to the fact that a lot of items will be manufactured depending only upon the type and need of the customer. 11This means that household-level production will be much preferred due to broader imagination and creativity of human being. Another implication is that the manufacturing process of any item can be highly customized because altering the items will not require tooling or intensive software development.12 These simplified production processes that were...

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Section: Roll-to-roll Printing (Rtr)mentioning

confidence: 99%

Advances in 2D/3D Printing of Functional Nanomaterials and Their Applications

Choi

Das

Theodore³

et al. 2015

ECS J. Solid State Sci. Technol.

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“…For the cost-effective fabrication of large-area plastic optical films, roll-to-roll (R2R) manufacturing was always an ideal method. In the present work, two kinds of roll-to-roll embossing methods have been reported: roll-to-roll UV embossing [1][2][3][4][5][6] and the roll-to-roll hot embossing process [7][8][9][10][11]. In the roll-to-roll UV embossing process, UV-curable resin was coated on a transparent plastic film.…”

Section: Introductionmentioning

confidence: 99%

Development of a continuous roll-to-roll processing system for mass production of plastic optical film

Chang

Tsai

2015

J. Micromech. Microeng.

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This paper reports a highly effective method for the mass production of large-area plastic optical films with a microlens array pattern based on a continuous roll-to-roll film extrusion and roller embossing process. In this study, a thin steel mold with a micro-circular hole array pattern is fabricated by photolithography and a wet chemical etching process. The thin steel mold was then wrapped onto a metal cylinder to form an embossing roller mold. During the roll-to-roll process operation, a thermoplastic raw material (polycarbonate grains) was put into the barrel of the plastic extruder with a flat T-die. Then, the molten polymer film was extruded and immediately pressed against the surface of the embossing roller mold. Under the proper processing conditions, the molten polymer will just partially fill the micro-circular holes of the mold and due to surface tension form a convex lens surface. A continuous plastic optical film with a microlens array pattern was obtained. Experiments are carried out to investigate the effect of plastic microlens formation on the roll-to-roll process. Finally, the geometrical and optical properties of the fabricated plastic optical film were measured and proved satisfactory. This technique shows great potential for the mass production of large-area plastic optical films with a microlens array pattern.

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“…Introduction: Micronanoimprint technology has been extensively developed since it was first proposed by Chou et al in 1995 [1,2]. In recent years, many related technologies and their applications [3][4][5] have emerged constantly in this area. The continuous roll-to-roll (R2R) technique can provide a solution for the high resolution, low cost and large-scale throughput of the reproducing microstructures.…”

mentioning

confidence: 99%

Bubble defect control in low‐cost roll‐to‐roll ultraviolet imprint lithography

Shen

et al. 2014

Micro & Nano Letters

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To obtain high quality patterns in ultraviolet roll-to-roll (R2R) imprinting lithography in the atmospheric environment with industrial resins, air bubble defects and the resulting distortion should be avoided in the process. In this reported work, the formation mechanism of the bubble defects is studied systematically with experiments and numerical analysis. The results show that the unsuitable resin coating method mainly contributes to the bubble defects in resin. On the basis of the above conclusions, an improved coating method is proposed in order to reduce the bubbles in the R2R process. This improvement can be applied to the replication of high quality patterns in R2R imprinting with low-cost industrial resins.

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Optimal design and fabrication of a light guide film with roll to roll process

Cited by 9 publications

References 13 publications

Advances in 2D/3D Printing of Functional Nanomaterials and Their Applications

Advances in 2D/3D Printing of Functional Nanomaterials and Their Applications

Development of a continuous roll-to-roll processing system for mass production of plastic optical film

Bubble defect control in low‐cost roll‐to‐roll ultraviolet imprint lithography

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