Force uniformity control for large-area roll-to-roll process

Nguyen, Truong Sinh; Lee, Seung–Hyun; Kim, Ga Eul; Kwon, Sin; Kim, Kyung-Rok; Park, Pyoungwon; Kim, Kwang-Young; Kim, Se‐Ho; Choi, Yun‐Jaie; Kim, Kyunghoon

doi:10.1063/5.0059365

Cited by 3 publications

(3 citation statements)

References 29 publications

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“…Furthermore, no significant differences in ∆ h were found between the MAPI and manual stitching processes because ∆ h is mainly related to the residual layer thickness, which is determined by various parameters including the imprint pressure, resin viscosity, and initial amount of applied resin, rather than the stitching process 42 . Thus, it is expected that this ∆ h issue can be addressed with an advanced resin dispensing system, further process optimization 43 , 44 , or improved fabrication process of the MAPI stamp (Supplementary Fig. 4c ).…”

Section: Resultsmentioning

confidence: 99%

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

et al. 2023

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The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, we propose a mark-less alignment by the pattern itself method inspired by moiré technique, which uses the Fourier spectral analysis of moiré patterns formed by superposed identical patterns for alignment. This method is capable of fabricating scalable functional surfaces and imprint molds with quasi-seamless and alignment mark-free patterning. By harnessing the rotational invariance property in the Fourier transform, our approach is confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces.

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Section: Resultsmentioning

confidence: 99%

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

et al. 2023

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“…Furthermore, no signi cant differences in ∆h were found between the SPA and conventional manual stitching processes because ∆h is mainly related to the residual layer thickness, which is determined by various parameters including the imprint pressure, resin viscosity, and initial amount of applied resin, rather than the stitching process 43 . Thus, it is expected that this ∆h issue can be addressed with an advanced resin dispensing system or further process optimization 44,45 .…”

Section: Evaluation Of the Spa-based Stitching Processmentioning

confidence: 99%

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

Kim

Seo

Lee

et al. 2022

Preprint

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The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, a self-pattern alignment (SPA) method inspired by moiré engineering is proposed to fabricate scalable functional surfaces and flexible imprint molds with quasi-seamless and alignment mark-free patterning, which is based on the Fourier spectral analysis of moiré patterns formed by superposed identical patterns. By harnessing the rotational invariance property in the Fourier transform, SPA was confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces.

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“…Recently, a few studies have addressed the bending problem that occurs in R2R systems when operating in a large area, and several methods have been proposed to compensate for the deformation of the roller system, such as the use of one or more additional rollers to eliminate bending [43,44]. However, these studies only deal with specific cases from the authors' research, and the results cannot be applied to many different cases, as the R2R system varies in size in terms of geometry and processing parameters.…”

Section: Introductionmentioning

confidence: 99%

Multi-Geometry Parameters Optimization of Large-Area Roll-to-Roll Nanoimprint Module Using Grey Relational Analysis and Artificial Neural Network

Nguyen

Gafurov

et al. 2023

Polymers

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Micro- and nanofabrication on polymer substrate is integral to the development of flexible electronic devices, including touch screens, transparent conductive electrodes, organic photovoltaics, batteries, and wearable devices. The demand for flexible and wearable devices has spurred interest in large-area, high-throughput production methods. Roll-to-roll (R2R) nanoimprint lithography (NIL) is a promising technique for producing nano-scale patterns rapidly and continuously. However, bending in a large-scale R2R system can result in non-uniform force distribution during the imprinting process, which reduces pattern quality. This study investigates the effects of R2R imprinting module geometry parameters on force distribution via simulation, using grey relational analysis to identify optimal parameter levels and ANOVA to determine the percentage of each parameter contribution. The study also investigates the length and force ratio on a backup roller used for bending compensation. The simulation results and the artificial neural network (ANN) model enable the prediction of nip pressure and force distribution non-uniformity along the roller, allowing the selection of the optimal roller geometry and force ratio for minimal non-uniformity on a specific R2R system. An experiment was conducted to validate the simulation results and ANN model.

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Force uniformity control for large-area roll-to-roll process

Cited by 3 publications

References 29 publications

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

Multi-Geometry Parameters Optimization of Large-Area Roll-to-Roll Nanoimprint Module Using Grey Relational Analysis and Artificial Neural Network

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