Roll to Roll Manufacturing and In-Line Imaging and Characterization of Functional Films

N. Glassmaker, Ye Mi, M. Cakmak, A. Shakouri
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引用次数: 1

Abstract

Roll-to-roll manufacturing is a promising platform to produce low cost, high quality electrical components and sensors for Internet of Things (IoT) applications. Within the roll-to-roll laboratories at Purdue University, a range of processes and machines have been developed to: 1) print patterns of conductive and sensing materials for use in electronic sensors, 2) cast films precisely with integrated functional materials, and 3) monitor quality of the printing and casting processes in-line in real time. A major development is the custom-designed and built Maxwell coating machine, which has enabled substantial quality improvements in slot-die coatings, as demonstrated by precise in-line thickness monitoring and imaging. As an illustrative example, we will show how we converted a design for a printed ion-selective electrode from a batch process to a roll-to-roll process. In-line process monitoring of coating thickness allowed us to identify high variability in the coating thickness due to an interaction between underlying printed electrodes and the drying process. By modifying the drying process, we demonstrated a substantial improvement as evidenced by the same in-line measurement technique. The overall process integrates several existing machines and processes in a novel way to create functional parts continuously, with data on individual parts gathered in real time.
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卷对卷制造和功能薄膜的在线成像和表征
卷对卷制造是一个很有前途的平台,可以为物联网(IoT)应用生产低成本、高质量的电子元件和传感器。在普渡大学的卷对卷实验室里,一系列的工艺和机器已经被开发出来:1)打印用于电子传感器的导电和传感材料的图案,2)用集成的功能材料精确地铸造薄膜,3)实时在线监控印刷和铸造过程的质量。一个主要的发展是定制设计和制造的Maxwell涂层机,它使槽模涂层的质量得到了实质性的提高,正如精确的在线厚度监测和成像所证明的那样。作为一个说明性的例子,我们将展示我们如何将印刷离子选择电极的设计从批处理转换为卷对卷处理。涂层厚度的在线过程监测使我们能够识别由于底层印刷电极和干燥过程之间的相互作用而导致的涂层厚度的高度可变性。通过修改干燥过程,我们展示了一个实质性的改进,证明了同样的在线测量技术。整个过程以一种新颖的方式集成了几个现有的机器和过程,以连续地创建功能部件,实时收集单个部件的数据。
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