A flexographic printing method for battery fabrication was presented. Key criteria for developing functional flexographic inks were established. A variety of MnO 2 composite cathode inks were developed and analyzed. A PSBR based ink showed excellent printability and electrochemical performance. a b s t r a c tA novel roll-to-roll flexographic printing process for rechargeable zinc-based battery manufacturing was presented in this paper. Based on the fundamental operating mechanism of flexography, key criteria for developing functional flexographic printing inks were established, including composite ink rheology (steady-state viscosity and yield stress), ink wettability as well as ink dispersing qualities. A variety of MnO 2 cathode inks were developed and analyzed comprehensively based on these criteria. A novel type of aqueous cathode ink based on PSBR polymeric binder showed excellent flexographic printability as well as promising electrochemical performance.
A choice-based conjoint study was conducted sampling 400 individuals to determine their preference for
The purpose of this study is to document current cost-estimating practices used in commercial digital printing. A research study was conducted to determine the use of cost-estimating in commercial digital printing companies. This study answers the questions: 1) What methods are currently being used to estimate digital printing? 2) What is the relationship between estimating and pricing digital printing? 3) To what extent, if at all, do digital printers use fullabsorption, all-inclusive hourly rates for estimating?Three different digital printing models were identified: 1) Traditional print providers, who supplement their offset presswork with digital printing for short-run color and versioned commercial print; 2) "Low-touch" print providers, who leverage the power of the Internet to streamline business transactions with digital storefronts; 3) Marketing solutions providers, who see printing less as a discrete manufacturing process and more as a component of a complete marketing campaign. Each model approaches estimating differently.Understanding and predicting costs can be extremely beneficial. Establishing a reliable system to estimate those costs can be somewhat challenging though. Unquestionably, cost-estimating digital printing will increase in relevance in the years ahead, as margins tighten and cost knowledge becomes increasingly more critical.
The lightweight and bendable features of printed flexible electronics are increasingly attractive. Currently stretchable silver inks are formulated for wide traces, typically larger than 2 mm. To attach ultra-thin silicon chips that have fine pitch onto printed organic substrate, it is necessary to print fine trace width/space that matches the pitch of the chips, which may be less than 200 microns. This paper presents the development and optimization of the screen printing process for printing stretchable silver ink onto stretchable thermoplastic polyurethane (TPU) substrate. A test vehicle was designed including 50 μm/5 mm (line width/line length) to 350 μm/35 mm lines (at 4 biases). The stretchable ink selected was DuPont PE 873 and Dupont's PE 5025 ink (non-stretchable conductive flake silver) was used as a “control” to baseline the printing process. The substrate used was Bemis TPU ST604. The experiment was done on a DEK Horizon 03i printer. A DEK squeegee 200 (Blue) and a DEK 265 flood bar (200 mm) were used. A 2-level factorial design with three replicates was selected to investigate the effect of process parameters on the quality of prints. The quality of the prints is characterized by 1) resistance of traces, 2) sheet resistance, 3) z-axis height, and 4) trace width/spacing. We observed significant noise in the z-axis printed silver ink height measured by profilometry and concluded z-axis height is not a good response variable for characterizing screen printing stretchable silver ink onto TPU substrate, mainly due to high roughness of the TPU substrate. We proposed calculated sheet resistance based on the measured resistance value, trace width, and trace length, which can replace trace height measurements on rough profile substrates. We found that squeegee pressure and emulsion thickness have statistically significant effects on calculated sheet resistance of print traces while print speed does not have statistically significant effects. In our experiment setting levels, the lower the squeegee pressure, the lower the calculated sheet resistance that is achieved. The emulsion with higher emulsion over mesh (EOM) is better than the emulsion with lower EOM since it can achieve lower sheet resistance. After optimizing the screen printing process, we were able to print 100 μm (4 mils) trace width and spacing with high consistency.
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