Roll-to-Roll Microcontact Printing of Flexible Aluminum Substrates Using Octadecylphosphonic Acid (ODPA)

Merian, Chris; Du, Xian; Hardt, David E.; Al‐Qahtani, Hussain

doi:10.1115/imece2015-51184

Cited by 4 publications

(5 citation statements)

References 17 publications

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“…For optical techniques, the droplet size is measured from the captured images by applying image processing. A popular method for recognizing circles and calculating their diameters is the circle Hough transform (CHT) [1,6,11,16]. The circle candidates are produced by 'voting' in the Hough parameter space and then selecting the local maxima in an accumulator matrix.…”

Section: Circle Detectionmentioning

confidence: 99%

“…For pattern recognition applications, small droplet size and dense droplet distribution will lead to smooth, precise, and accurate segmentation of surface patterns [1,6]. Hence, it is necessary to keep most of the droplets in the early growing phase via direct condensation before any coalescence events occur by controlling an equilibrium between condensation and evaporation.…”

Section: Theory Of Condensation and Evaporationmentioning

confidence: 99%

“…The formed CFs on surfaces can be further segmented for pattern recognition and measurement. CFs offer a simple, nondestructive, and cost-effective imaging method for surface inspection that may not be accessible by other techniques [1]. * Author to whom any correspondence should be addressed.…”

Section: Introductionmentioning

confidence: 99%

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Consistent optical surface inspection based on open environment droplet size-controlled condensation figures

Yan¹,

Ma²,

Du³

2021

Meas. Sci. Technol.

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Condensation figure (CF) is a simple and cost-effective method to inspect patterns and defects on product surfaces. This inspection method is based on energy differentials on surfaces. Due to wettability contrast, water droplets are preferentially nucleated and grown on hydrophilic regions. The formed CF can further be segmented for the recognition and measurement of the patterns on the surfaces. The state-of-the-art CF methods are close-environmental, while controlled open-environmental CF has broader applications in manufacturing and quality inspection. The lack of open-environmental CF for such applications is mostly because of the unavailable droplet size control methods. In this paper, we designed a high-resolution optical surface inspection system based on open environment droplet-size-controlled CFs. This is done by real-time imaging and recognizing the condensed droplet sizes and densities on surfaces, and accordingly tuning the vaporization and evaporation of droplets on the surface by the vapor flow rate. Our experimental results show that the average diameter of droplets can be controlled below 3.5 µm in a laboratory setup for different metal substrates. We also test the system for inspecting self-assembled monolayer patterns with line width of 5 µm on a gold surface; this can be promisingly used for online quality monitoring and in-process control of printed patterns in flexible devices manufacturing.

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Section: Circle Detectionmentioning

confidence: 99%

Section: Theory Of Condensation and Evaporationmentioning

confidence: 99%

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Consistent optical surface inspection based on open environment droplet size-controlled condensation figures

Yan¹,

Ma²,

Du³

2021

Meas. Sci. Technol.

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“…It is also compatible with roll‐to‐roll processing and can be scaled to a large area at a low cost. [ 44,45 ] Unfortunately, the time taken to deposit the patterned PFDMA layer by microcontact printing was ≈10 s, which is not compatible with continuous roll‐to‐roll processing, and the electrode FoM was not competitive with ITO glass; 68 versus ≈400.…”

Section: Introductionmentioning

confidence: 99%

High Performance Transparent Silver Grid Electrodes for Organic Photovoltaics Fabricated by Selective Metal Condensation

et al. 2023

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Silver grid electrodes on glass and flexible plastic substrates with performance that exceeds that of commercial indium‐tin oxide (ITO) coated glass are reported and show their suitability as a drop‐in replacement for ITO glass in solution‐processed organic photovoltaics (OPVs). When supported on flexible plastic substrates these electrodes are stable toward repeated bending through a small radius of curvature over tens of thousands of cycles. The grid electrodes are fabricated by the unconventional approach of condensation coefficient modulation using a perfluorinated polymer shown to be far superior to the other compounds used for this purpose to date. The very narrow line width and small grid pitch that can be achieved also open the door to the possibility of using grid electrodes in OPVs without a conducting poly(3,4‐ethylenedioxythiophene‐poly(styrenesulfonate) (PEDOT: PSS) layer to span the gaps between grid lines.

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“…The roll-to-roll (R2R) manufacturing systems are known for their higher efficiency of mass production compared to batchto-batch processing systems. Generally, a R2R machine conveys a continuous flexible web, composed of thin plastic, metal, or paper, through various R2R processing units, such as microcontact printing [1,2]. Most R2R machines require precise and consistent moving speed and tension control on the web.…”

Section: Introductionmentioning

confidence: 99%

Real-time web tension prediction using web moving speed and natural vibration frequency

Yan¹,

Du²

2020

Meas. Sci. Technol.

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Precise web tension measurement is critical for web handling and process control in roll-to-roll (R2R) manufacturing systems. Calculating web tension by using out-of-plane vibration measurement offers a contactless solution to tension measurement during the R2R process, which is suitable for situations where contacting web tension measurement sensors cannot be applied. In this paper, a real-time prediction of web tension based on contactless sensing of out-of-plane web vibration is presented for the first time. We design and test a fast frequency estimation algorithm, based on the Fourier series, which solves the frequency resolution problem currently existing in real-time applications when conventional FFT is applied. Our simulation results show that the proposed method has an accurate estimation of frequency under harmonics and white Gaussian noise based on few observed cycles. A R2R testbed was built for testing the real-time performance of the proposed algorithm including accuracy, robustness, and computation speed. The experimental results on the testbed show that the proposed method can predict the web tension with an error less than 10% for various tension values and track the tension changes within one analysis window of 50 ms.

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Roll-to-Roll Microcontact Printing of Flexible Aluminum Substrates Using Octadecylphosphonic Acid (ODPA)

Abstract: Soft-lithography, or the printing of self-assembling molecular inks at micro or sub-micron scale holds the promise of large-scale surface patterning for a variety of applications.

Cited by 4 publications

References 17 publications

Consistent optical surface inspection based on open environment droplet size-controlled condensation figures

Consistent optical surface inspection based on open environment droplet size-controlled condensation figures

High Performance Transparent Silver Grid Electrodes for Organic Photovoltaics Fabricated by Selective Metal Condensation

Real-time web tension prediction using web moving speed and natural vibration frequency

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