Fabrication of micro‐ and nanostructures at line‐speed of 60 m min−1 by large‐area roll‐to‐roll extrusion coating is demonstrated. Nanopillars with diameters 80 nm and heights 100 nm are replicated in polypropylene. The main limiting factor for replication on nanoscale is the retardation time for solidification of the melt.
Lab-scale plasmonic color printing using nano-structured and subsequently metallized surfaces have been demonstrated to provide vivid colors. However, upscaling these structures for large area manufacturing is extremely challenging due to the requirement of nanometer precision of metal thickness. In this study, we have investigated a plasmonic color meta-surface design that can be easily upscaled. We have demonstrated the feasibility of fabrication of these plasmonic color surfaces by a high-speed roll-to-roll method, comprising roll-to-roll extrusion coating at 10 m min creating a polymer foil having 100 nm deep pits of varying sub-wavelength diameter and pitch length. Subsequently this polymer foil was metallized and coated also by high-speed roll-to-roll methods. The perceived colors have high tolerance towards the thickness of the metal layer, when this thickness exceeds the depths of the pits, which enables the robust high-speed fabrication. This finding can pave the way for plasmonic meta-surfaces to be implemented in a broader range of applications such as printing, memory, surface enhanced Raman scattering (SERS), biosensors, flexible displays, photovoltaics, security, and product branding.
We demonstrate the
use of roll-to-roll extrusion coating (R2R-EC)
for fabrication of nanopatterned polypropylene (PP) foils with strong
antiwetting properties. The antiwetting nanopattern is originated
from textured surfaces fabricated on silicon wafers by a single-step
method of reactive ion etching with different processing gas flow
rates. We provide a systematic study of the wetting properties for
the fabricated surfaces and show that a controlled texture stretching
effect in the R2R-EC process is instrumental to yield the superhydrophobic
surfaces with water contact angles approaching 160° and droplet
roll-off angles below 10°.
a b s t r a c tSurface roughness or texture is the most visible property of any object, including injection molded plastic parts. Roughness of the injection molding (IM) tool cavity directly affects not only appearance and perception of quality, but often also the function of all manufactured plastic parts. So called "optically smooth" plastic surfaces is one example, where low roughness of a tool cavity is desirable. Such tool surfaces can be very expensive to fabricate using conventional means, such as abrasive diamond polishing or diamond turning. We present a novel process to coat machined metal parts with hydrogen silsesquioxane (HSQ) to reduce their surface roughness. Results from the testing of surfaces made from two starting roughnesses are presented; one polished with grit 2500 sandpaper, another with grit 11.000 diamond polishing paste. We characterize the two surfaces with AFM, SEM and optical profilometry before and after coating. We show that the HSQ coating is able to reduce peak-to-valley roughness more than 20 times on the sandpaper polished sample, from 2.44(±0.99) m to 104(±22) nm and more than 10 times for the paste polished sample from 1.85(±0.63) m to 162(±28) nm while roughness averages are reduced 10 and 3 times respectively. We completed more than 10,000 injection molding cycles without detectable degradation of the HSQ coating. This result opens new possibilities for molding of affordable plastic parts with perfect surface finish.
Coral reefs are constructed by calcifying coral animals that engage in a symbiosis with dinoflagellate microalgae harboured in their tissue. The symbiosis takes place in the presence of steep and dynamic gradients of light, temperature and chemical species that are affected by the structural and optical properties of the coral and their interaction with incident irradiance and water flow. Microenvironmental analyses have enabled quantification of such gradients and bulk coral tissue and skeleton optical properties, but the multi-layered nature of corals and its implications for the optical, thermal and chemical microenvironment remains to be studied in more detail. Here, we present a multiphysics modelling approach, where three-dimensional Monte Carlo simulations of the light field in a simple coral slab morphology with multiple tissue layers were used as input for modelling the heat dissipation and photosynthetic oxygen production driven by photon absorption. By coupling photon, heat and mass transfer, the model predicts light, temperature and O
2
gradients in the coral tissue and skeleton, under environmental conditions simulating, for example, tissue contraction/expansion, symbiont loss via coral bleaching or different distributions of coral host pigments. The model reveals basic structure–function mechanisms that shape the microenvironment and ecophysiology of the coral symbiosis in response to environmental change.
This paper investigates a novel, very high throughput, roll-to-roll (R2R) process for nanostructuring of polymer foils, called R2R extrusion coating. It has the potential to accelerate the integration of nanostructured materials in consumer products for a variety of applications, including optical, technical, and functional surfaces and devices. In roll-to-roll extrusion coating, a molten polymer film is extruded through a flat die forming a melt curtain, and then laminated onto a carrier foil. The lamination occurs as the melt curtain is pressed between a cooling roller and a counter roller. By mounting a nanostructured metal shim on the surface of the cooling roller, the relief structure from the shim can be replicated onto a thermoplastic foil. Among the benefits of Poil, the process are availability of a wide range of commercial extruders, off-the-shelf extrusion grade polymers, functional additives, polymeric materials with good diffusion barrier properties, and the overall maturity of the technology [S. H. Ahn and L. J. Guo, Adv. Mater. 20, 2044 (2008)]. In this article, the authors demonstrate replication of nanopits and nanopillars with diameters between 40 and 120 nm and depth/height of 100 nm. The best replication was achieved in polypropylene, by running at high roller line-speed of 60 m/min, and high cooling roller temperature of 70 °C. Replication in other common polymers like polyethylene and polystyrene was not possible for the parameter range used for the investigation.
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