Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing
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 ge...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-05-01
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| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/15/11/2478 |
| _version_ | 1797596887928274944 |
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| author | Hojin Jeon Jaehyun Noh Minho Jo Changbeom Joo Jeongdai Jo Changwoo Lee |
| author_facet | Hojin Jeon Jaehyun Noh Minho Jo Changbeom Joo Jeongdai Jo Changwoo Lee |
| author_sort | Hojin Jeon |
| collection | DOAJ |
| description | 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%. |
| first_indexed | 2024-03-11T02:59:07Z |
| format | Article |
| id | doaj.art-ed934382de9a4124932c77e91333980e |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-11T02:59:07Z |
| publishDate | 2023-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-ed934382de9a4124932c77e91333980e2023-11-18T08:26:03ZengMDPI AGPolymers2073-43602023-05-011511247810.3390/polym15112478Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll ManufacturingHojin Jeon0Jaehyun Noh1Minho Jo2Changbeom Joo3Jeongdai Jo4Changwoo Lee5Department of Mechanical Design and Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of KoreaDepartment of Mechanical Design and Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of KoreaDepartment of Mechanical Design and Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of KoreaDepartment of Mechanical Engineering, Stevens Institute of Technology, 1 Castle Point Terrace, Hoboken, NJ 07030, USADepartment of Printed Electronics, Korea Institute of Machinery and Materials, 156, Gajeongbuk-ro, Yuseong-gu, Daejeon 34103, Republic of KoreaDepartment of Mechanical and Aerospace Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of KoreaA 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%.https://www.mdpi.com/2073-4360/15/11/2478functional filmink spreadabilitylayered structuresroll-to-rollslot-die coatingsurface roughness |
| spellingShingle | Hojin Jeon Jaehyun Noh Minho Jo Changbeom Joo Jeongdai Jo Changwoo Lee Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing Polymers functional film ink spreadability layered structures roll-to-roll slot-die coating surface roughness |
| title | Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing |
| title_full | Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing |
| title_fullStr | Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing |
| title_full_unstemmed | Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing |
| title_short | Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing |
| title_sort | layer by layer engineered flexible functional film fabrication with spreadability control in roll to roll manufacturing |
| topic | functional film ink spreadability layered structures roll-to-roll slot-die coating surface roughness |
| url | https://www.mdpi.com/2073-4360/15/11/2478 |
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