Roll-to-roll manufacturing process elements and recent advances

425 Pages·2018·20.906 MB·English

by  Cakmak, Mukerrem, Greener, Jehuda, Pearson, Glen Hamilton

Roll‐to‐Roll Manufacturing

Roll‐to‐Roll Manufacturing
Process Elements and Recent Advances
Edited by
Jehuda Greener, Glen Pearson, and Miko Cakmak
This edition first published 2018
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Library of Congress Cataloging‐in‐Publication Data
Names: Greener, Jehuda, editor. | Pearson, Glen Hamilton, 1948– editor. |
Cakmak, Mukerrem, editor.
Title: Roll-to-roll manufacturing : process elements and recent advances / edited by Jehuda Greener,
Glen Pearson, Miko Cakmak.
Description: Hoboken, NJ : John Wiley & Sons, 2018. | Includes bibliographical references and index. |
Identifiers: LCCN 2017043485 (print) | LCCN 2017052231 (ebook) | ISBN 9781119163800 (pdf) |
ISBN 9781119163817 (epub) | ISBN 9781119162209 (cloth)
Subjects: LCSH: Manufacturing processes–Technological innovations. | Flexible electronics–Processing.
Classification: LCC TS183 (ebook) | LCC TS183 .R65 2018 (print) | DDC 670.42–dc23
LC record available at https://lccn.loc.gov/2017043485
Cover Design: Wiley
Cover Images: Courtesy of Miko Cakmak; © Iaremenko Sergii/Shutterstock
Set in 10/12pt Warnock by SPi Global, Pondicherry, India
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
For Helena, Maya, Eli, Karen, Emre, and Gulgun

vii
Contents
Preface xiii
1 Roll‐to‐Roll Manufacturing: An Overview 1
Jehuda Greener
1.1 Introduction 1
1.2 R2R Operation Overview 5
1.3 Process Economics 9
1.4 Environmental, Health, and Safety Considerations 13
1.5 Summary 15
References 15
2 Coating and Solidification 19
E. J. Lightfoot and E. D. Cohen
2.1 Coating Methods 19
2.1.1 Coating Fundamentals 20
2.1.1.1 Wetting 20
2.1.1.2 Coating Distribution 22
2.1.1.3 The Coating Window 22
2.1.2 Coating Hardware 24
2.1.2.1 Pre‐metered Coating 24
2.1.2.2 Self‐Metered Coating 27
2.1.3 Selecting a Coating Method 39
2.2 Drying and Curing 43
2.2.1 Principles 43
2.2.1.1 Choice of Solidification Method 43
2.2.1.2 Coupled Mass and Energy Transfer 44
2.2.1.3 Infrared Drying 48
2.2.1.4 UV Curing 48
2.2.1.5 E‐Beam Curing 49
2.2.1.6 Dielectric Drying 49
2.2.1.7 The Drying Curve 50
2.2.2 Hardware 52
2.2.2.1 Conduction 52
viii Contents
2.2.2.2 Convection 52
2.2.2.3 IR Drying 56
2.3 Defect Management 58
2.3.1 Characterizing Defects 58
2.3.2 Defect Naming 58
2.3.3 Online Defect Characterization Systems 58
2.3.4 Defect Troubleshooting 59
2.3.4.1 Contamination 59
2.3.4.2 Substrate Deficiencies 59
2.3.4.3 Liquid Coating Quality 60
2.3.4.4 Unsuitable Coating Method 60
2.3.4.5 Inadequate Design of Coating Line Equipment 60
2.3.4.6 Deterioration of Coating Line Equipment 60
2.3.4.7 Drying‐Induced Defects 60
2.3.4.8 Variations in Web Handling System 61
2.3.4.9 Inadequate Operating Procedures and Training 61
2.3.4.10 Key Variables Not Properly Controlled 61
References 61
3 Drying of Polymer Solutions: Modeling and Real‐Time
Tracking of the Process 65
S. Shams Es‐haghi and Miko Cakmak
3.1 Introduction 65
3.2 Modeling of the Drying Process 67
3.3 Real‐Time Tracking of the Drying Process of Polymer
Solutions 80
3.3.1 Real‐Time Measurement System 80
3.3.2 Drying Process of Polyimide/N,N‐Dimethylformamide 
Solutions 84
3.3.3 Real‐Time Study of Drying and Imidization of Polyamic
Acid/NMP Solution 91
3.3.4 Development of Optical Gradient During Evaporation
of Solvent 97
3.3.5 Effect of Organoclay and Graphene Oxide on the Drying
Process of PAI/DMAc Solution 99
3.3.6 Real‐Time Drying Study of Polyetherimide/NMP 102
3.4 Conclusions 104
References 106
4 In‐Line Vacuum Deposition 111
C. A. Bishop
4.1 Introduction 111
4.2 Substrates 112