Theories and Control Technologies for Web Handling in the Roll-to-Roll Manufacturing Process

Lee, Jongsu; Byeon, Junhyeon; Lee, Chang Woo

doi:10.1007/s40684-019-00185-3

Cited by 40 publications

(18 citation statements)

References 88 publications

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“…The surface roughness of the web decreases with increasing tension; accordingly, the surface energy of the web is increased. The ink transferred to the web is more widened after the ink transfer, and the printed pattern is more uniform, which could decrease the resistance [31,32]. The increase in the web speed could increase the shear force generated in the ink between the engraved cell and the web during ink transfer.…”

Section: Methodsmentioning

confidence: 99%

Resistance Control of an Additively Manufactured Conductive Layer in Roll-to-Roll Gravure Printing Systems

Lee

Kim

et al. 2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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Flexible pressure sensors, which are employed in robotic arms and electronic skin, are conventionally prepared using methods such three-dimensional printing, laser scribing, and spray coating. However, they are time-consuming and unsuitable for large-scale production. Thus, to overcome these limitations, roll-to-roll (R2R)-based fabrication techniques have been employed for low-cost mass production of flexible pressure sensors. Gravure printing is a promising R2R based technique, but it faces limitations in terms of ink-flow and printing defects causing short circuit, which may affect the performance of printed electronic devices. In this study, we analyzed the effects of printing conditions, web speed, tension, and nip pressure on the drag-out tail defects and conductance in the gravel printing process. We statistically optimized the optimal conditions to obtain minimum drag-out tail defects and conductance using a Box-Behnken design. We also fabricated two flexible pressure capacitive sensors using the conductive patterns to verify optimal conditions. Our results showed that the resistance decreased with increasing web speed, tension, and nip pressure, whereas the drag-out tail increased with increasing tension and nip pressure and decreasing web speed. Additionally, under the optimal conditions, the resistance and drag-out tail severity were improved by 74% and 53%, respectively, over those of the conventionally printed pattern. Finally, using the two flexible pressure capacitive sensors, we showed that the sensor using the conductive pattern had a higher sensitivity after optimization.

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Section: Methodsmentioning

confidence: 99%

Resistance Control of an Additively Manufactured Conductive Layer in Roll-to-Roll Gravure Printing Systems

Lee

Kim

et al. 2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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“…The flexographic printing uses an additional flexible relief plate to lower the requirements on inks and property of substrates [218]. Then, R2R printing is a mature and extensively used method for the largearea manufacturing of electronic devices, as a result of its high processing speed [219]. The gravure and flexographic printing methods are intrinsically compatible with the R2R printing.…”

Section: Printing Wearable Sensorsmentioning

confidence: 99%

Eco-friendly Strategies for the Material and Fabrication of Wearable Sensors

Liu

Shang

et al. 2020

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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Wearable sensors are attracting great attentions due to their potential applications in human health monitoring and caring systems. The wide utilization of wearable electronics may cause great burden to the environment, due to the vast contaminants generated in their fabrication and after their usage. Consequently, great efforts are devoted to the eco-friendly strategies for the material and fabrication in wearable sensors. Herein, recent advantages in developing wearable sensors with eco-friendly materials and green manufacturing approaches are reviewed. The functional materials with accessibility, recoverability and degradability have participated in the sensors as substrates, sensing elements and conductors. The fabrication strategies, from facile manual schemes to low-emission automated techniques are also introduced with their merits and demerits. Finally, the existing challenges and future opportunities in this field are summarized.

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“…The roll-to-roll manufacturing (R2R) process has become a subject of interest because of its low cost and mass production capability [1]. With this process, large-area functional layers can be fabricated on a flexible polymer substrate using various printing or coating techniques, such as blade coating, spray coating, and slot-die coating [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Numerical Modeling of Ink Widening and Coating Gap in Roll-to-Roll Slot-Die Coating of Solid Oxide Fuel Cell Electrolytic Layer

Kim

Lee

et al. 2020

Polymers

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Slot-die coatings are advantageous when used for coating large-area flexible devices; in particular, the coating width can be controlled and simultaneous multi-layer coatings can be processed. To date, the effects of ink widening and the coating gap on the coating thickness have only been considered in a few studies. To this end, we developed two mathematical models to accurately estimate the coating width and thickness that consider these two effects. We used root mean square deviation (RMSD) to experimentally verify the developed method. When the coating gap was increased, the coating width increased and the coating thickness decreased. Experimental results showed that the estimated performances of the coating width and thickness models were as high as 98.46% and 95.8%, respectively. We think that the developed models can be useful for determining the coating conditions according to the ink properties to coat a functional layer with user-defined widths and thicknesses in both lab- and industrial-scale roll-to-roll slot-die coating processes.

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Theories and Control Technologies for Web Handling in the Roll-to-Roll Manufacturing Process

Cited by 40 publications

References 88 publications

Resistance Control of an Additively Manufactured Conductive Layer in Roll-to-Roll Gravure Printing Systems

Resistance Control of an Additively Manufactured Conductive Layer in Roll-to-Roll Gravure Printing Systems

Eco-friendly Strategies for the Material and Fabrication of Wearable Sensors

Numerical Modeling of Ink Widening and Coating Gap in Roll-to-Roll Slot-Die Coating of Solid Oxide Fuel Cell Electrolytic Layer

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