Fabrication of Thickness-Controllable Double Layer Electrolyte Using Roll-to-Roll Additive Manufacturing System

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

doi:10.1007/s40684-020-00200-y

Cited by 17 publications

(12 citation statements)

References 26 publications

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“…Considering the poor doctoring quality at low doctoring pressure, we fixed the doctoring pressure to 0.6 MPa. The drying temperature was set to 150 °C considering the curing temperature of the ink according to the drying time, determined by the length of the dryer and the maximum web speed in this experiment [29,30]. Figure 4 presents the images of the ink particle at (a) room temperature and (b) cured at 150 °C, respectively.…”

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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“…where w0 is the width of the slot-die coater and h is the coating gap. Equation ( 4) represents the coating thickness model developed in our previous studies for estimating the coating thickness considering the widening effect [21,22].…”

Section: Mathematical Modelingmentioning

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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“…Roll-to-roll systems are suitable candidates for achieving high speed and mass production of flexible functional devices, such as flexible printed electronics, solar cells, fuel cells, bioelectric sensors, and pressure capacitive sensors [ 1 , 2 , 3 , 4 , 5 , 6 , 7 ]. The slot-die coating process has the advantages of a large-area and pre-metered coating; therefore, it is used in the mass production of large-area functional layers [ 8 , 9 , 10 , 11 ]. Roll-to-roll slot-die coating systems consist of unwinding, infeeding, coating, drying, outfeeding, and rewinding sections [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Radial Stress on the Nanoparticle-Based Electrolyte Layer in a Center-Wound Roll with Roll-to-Roll Systems

Noh

Cho

et al. 2022

Nanomaterials

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Recently, slot-die coating based on the roll-to-roll process has been actively used to fabricate nanoparticle-based electrolyte layers because it is advantageous for high-speed processes and mass production of uniformly thick electrolyte layers. In this process, the fabricated electrolyte layer is stored as a wound roll throughout the rewinding process. We analyzed the defects and geometric changes in an electrolyte layer, i.e., gadolinium-doped cerium oxide (GDC), due to the radial stress in the wound roll. We found that the thickness of the coated layer could be decreased by increasing the radial stress, i.e., cracks can be generated in the coated layer if excessively high radial stress is applied to the wound-coated layer. More thickness changes and crack defects were generated with time due to the residual stress in the wound roll. Finally, we analyzed the effects of taper tension profiles on the defects of the coated layer in the wound roll and determined the taper tension profile to minimize defects.

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Fabrication of Thickness-Controllable Double Layer Electrolyte Using Roll-to-Roll Additive Manufacturing System

Cited by 17 publications

References 26 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

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

Effect of Radial Stress on the Nanoparticle-Based Electrolyte Layer in a Center-Wound Roll with Roll-to-Roll Systems

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