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Sample records for roll-to-roll processed polymer

  1. Flow behavior of polymers during the roll-to-roll hot embossing process

    NASA Astrophysics Data System (ADS)

    Deng, Yujun; Yi, Peiyun; Peng, Linfa; Lai, Xinmin; Lin, Zhongqin

    2015-06-01

    The roll-to-roll (R2R) hot embossing process is a recent advancement in the micro hot embossing process and is capable of continuously fabricating micro/nano-structures on polymers, with a high efficiency and a high throughput. However, the fast forming of the R2R hot embossing process limits the time for material flow and results in complicated flow behavior in the polymers. This study presents a fundamental investigation into the flow behavior of polymers and aims towards the comprehensive understanding of the R2R hot embossing process. A three-dimensional (3D) finite element (FE) model based on the viscoelastic model of polymers is established and validated for the fabrication of micro-pyramids using the R2R hot embossing process. The deformation and recovery of micro-pyramids on poly(vinyl chloride) (PVC) film are analyzed in the filling stage and the demolding stage, respectively. Firstly, in the analysis of the filling stage, the temperature distribution on the PVC film is discussed. A large temperature gradient is observed along the thickness direction of the PVC film and the temperature of the top surface is found to be higher than that of the bottom surface, due to the poor thermal conductivity of PVC. In addition, creep strains are demonstrated to depend highly on the temperature and are also observed to concentrate on the top layer of the PVC film because of high local temperature. In the demolding stage, the recovery of the embossed micro-pyramids is obvious. The cooling process is shown to be efficient for the reduction of recovery, especially when the mold temperature is high. In conclusion, this research advances the understanding of the flow behavior of polymers in the R2R hot embossing process and might help in the development of the highly accurate and highly efficient fabrication of microstructures on polymers.

  2. Aqueous processing of low-band-gap polymer solar cells using roll-to-roll methods.

    PubMed

    Andersen, Thomas R; Larsen-Olsen, Thue T; Andreasen, Birgitta; Böttiger, Arvid P L; Carlé, Jon E; Helgesen, Martin; Bundgaard, Eva; Norrman, Kion; Andreasen, Jens W; Jørgensen, Mikkel; Krebs, Frederik C

    2011-05-24

    Aqueous nanoparticle dispersions of a series of three low-band-gap polymers poly[4,8-bis(2-ethylhexyloxy)benzo(1,2-b:4,5-b')dithiophene-alt-5,6-bis(octyloxy)-4,7-di(thiophen-2-yl)(2,1,3-benzothiadiazole)-5,5'-diyl] (P1), poly[(4,4'-bis(2-ethylhexyl)dithieno[3,2-b:2',3'-d]silole)-2,6-diyl-alt-(2,1,3-benzothiadiazole)-4,7-diyl] (P2), and poly[2,3-bis-(3-octyloxyphenyl)quinoxaline-5,8-diyl-alt-thiophene-2,5-diyl] (P3) were prepared using ultrasonic treatment of a chloroform solution of the polymer and [6,6]-phenyl-C(61)-butyric acid methyl ester ([60]PCBM) mixed with an aqueous solution of sodium dodecylsulphate (SDS). The size of the nanoparticles was established using small-angle X-ray scattering (SAXS) of the aqueous dispersions and by both atomic force microscopy (AFM) and using both grazing incidence SAXS (GISAXS) and grazing incidence wide-angle X-ray scattering (GIWAXS) in the solid state as coated films. The aqueous dispersions were dialyzed to remove excess detergent and concentrated to a solid content of approximately 60 mg mL(-1). The formation of films for solar cells using the aqueous dispersion required the addition of the nonionic detergent FSO-100 at a concentration of 5 mg mL(-1). This enabled slot-die coating of high quality films with a dry thickness of 126 ± 19, 500 ± 25, and 612 ± 22 nm P1, P2, and P3, respectively for polymer solar cells. Large area inverted polymer solar cells were thus prepared based on the aqueous inks. The power conversion efficiency (PCE) reached for each of the materials was 0.07, 0.55, and 0.15% for P1, P2, and P3, respectively. The devices were prepared using coating and printing of all layers including the metal back electrodes. All steps were carried out using roll-to-roll (R2R) slot-die and screen printing methods on flexible substrates. All five layers were processed using environmentally friendly methods and solvents. Two of the layers were processed entirely from water (the electron transport layer and the active

  3. Towards roll-to-roll manufacturing of polymer photonic devices

    NASA Astrophysics Data System (ADS)

    Subbaraman, Harish; Lin, Xiaohui; Ling, Tao; Guo, L. Jay; Chen, Ray T.

    2014-03-01

    Traditionally, polymer photonic devices are fabricated using clean-room processes such as photolithography, e-beam lithography, reactive ion etching (RIE) and lift-off methods etc, which leads to long fabrication time, low throughput and high cost. We have utilized a novel process for fabricating polymer photonic devices using a combination of imprinting and ink jet printing methods, which provides high throughput on a variety of rigid and flexible substrates with low cost. We discuss the manufacturing challenges that need to be overcome in order to realize true implementation of roll-to-roll manufacturing of flexible polymer photonic systems. Several metrology and instrumentation challenges involved such as availability of particulate-free high quality substrate, development and implementation of high-speed in-line and off-line inspection and diagnostic tools with adaptive control for patterned and unpatterned material films, development of reliable hardware, etc need to be addressed and overcome in order to realize a successful manufacturing process. Due to extreme resolution requirements compared to print media, the burden of software and hardware tools on the throughput also needs to be carefully determined. Moreover, the effect of web wander and variations in web speed need to accurately be determined in the design of the system hardware and software. In this paper, we show the realization of solutions for few challenges, and utilizing these solutions for developing a high-rate R2R dual stage ink-jet printer that can provide alignment accuracy of <10μm at a web speed of 5m/min. The development of a roll-to-roll manufacturing system for polymer photonic systems opens limitless possibilities for the deployment of high performance components in a variety of applications including communication, sensing, medicine, agriculture, energy, lighting etc.

  4. Manufacturing Demonstration Facility: Roll-to-Roll Processing

    SciTech Connect

    Datskos, Panos G; Joshi, Pooran C; List III, Frederick Alyious; Duty, Chad E; Armstrong, Beth L; Ivanov, Ilia N; Jacobs, Christopher B; Graham, David E; Moon, Ji Won

    2015-08-01

    This Manufacturing Demonstration Facility (MDF)e roll-to-roll processing effort described in this report provided an excellent opportunity to investigate a number of advanced manufacturing approaches to achieve a path for low cost devices and sensors. Critical to this effort is the ability to deposit thin films at low temperatures using nanomaterials derived from nanofermentation. The overarching goal of this project was to develop roll-to-roll manufacturing processes of thin film deposition on low-cost flexible substrates for electronics and sensor applications. This project utilized ORNL s unique Pulse Thermal Processing (PTP) technologies coupled with non-vacuum low temperature deposition techniques, ORNL s clean room facility, slot dye coating, drop casting, spin coating, screen printing and several other equipment including a Dimatix ink jet printer and a large-scale Kyocera ink jet printer. The roll-to-roll processing project had three main tasks: 1) develop and demonstrate zinc-Zn based opto-electronic sensors using low cost nanoparticulate structures manufactured in a related MDF Project using nanofermentation techniques, 2) evaluate the use of silver based conductive inks developed by project partner NovaCentrix for electronic device fabrication, and 3) demonstrate a suite of low cost printed sensors developed using non-vacuum deposition techniques which involved the integration of metal and semiconductor layers to establish a diverse sensor platform technology.

  5. Silver front electrode grids for ITO-free all printed polymer solar cells with embedded and raised topographies, prepared by thermal imprint, flexographic and inkjet roll-to-roll processes.

    PubMed

    Yu, Jong-Su; Kim, Inyoung; Kim, Jung-Su; Jo, Jeongdai; Larsen-Olsen, Thue T; Søndergaard, Roar R; Hösel, Markus; Angmo, Dechan; Jørgensen, Mikkel; Krebs, Frederik C

    2012-09-28

    Semitransparent front electrodes for polymer solar cells, that are printable and roll-to-roll processable under ambient conditions using different approaches, are explored in this report. The excellent smoothness of indium-tin-oxide (ITO) electrodes has traditionally been believed to be difficult to achieve using printed front grids, as surface topographies accumulate when processing subsequent layers, leading to shunts between the top and bottom printed metallic electrodes. Here we demonstrate how aqueous nanoparticle based silver inks can be employed as printed front electrodes using several different roll-to-roll techniques. We thus compare hexagonal silver grids prepared using either roll-to-roll inkjet or roll-to-roll flexographic printing. Both inkjet and flexo grids present a raised topography and were found to perform differently due to only the conductivity of the obtained silver grid. The raised topographies were compared with a roll-to-roll thermally imprinted grid that was filled with silver in a roll-to-roll process, thus presenting an embedded topography. The embedded grid and the flexo grid were found to perform equally well, with the flexographic technique currently presenting the fastest processing and the lowest silver use, whereas the embedded grid presents the maximally achievable optical transparency and conductivity. Polymer solar cells were prepared in the same step, using roll-to-roll slot-die coating of zinc oxide as the electron transport layer, poly-3-hexylthiophene:phenyl-C(61)-butyric acid methyl ester (P3HT:PCBM) as the active layer and poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) as the top electrode, along with a flat bed screen printed silver grid. The power conversion efficiency (PCE) obtained for large area devices (6 cm(2)) was 1.84%, 0.79% and 1.72%, respectively, for thermally imprinted, inkjet and flexographic silver grids, tested outside under the real sun. Central to all three approaches was that they

  6. Roll-to-roll embossing of optical linear Fresnel lens polymer film for solar concentration.

    PubMed

    Zhang, XinQuan; Liu, Kui; Shan, Xuechuan; Liu, Yuchan

    2014-12-15

    Roll-to-roll manufacturing has been proven to be a high-throughput and low-cost technology for continuous fabrication of functional optical polymer films. In this paper, we have firstly studied a complete manufacturing cycle of linear Fresnel lens polymer film for solar concentration in the aspects of ultra-precision diamond machining of metal roller mold, roll-to-roll embossing, and measurement on film profile and functionality. A metal roller mold patterned with linear Fresnel lenses is obtained using single point diamond turning technique. The roller mold is installed onto a self-developed roll-to-roll UV embossing system to realize continuous manufacturing of linear Fresnel lens film. Profile measurement of the machined roller mold and the embossed polymer film, which is conducted using a stylus profilometer, shows good agreement between measured facet angles with designed ones. Functionality test is conducted on a solar simulation system with a reference solar cell, and results show that strong light concentration is realized. PMID:25607497

  7. Thermoresistive Strain Sensor and Positioning Method for Roll-to-Roll Processes

    PubMed Central

    Liao, Kuan-Hsun; Lo, Cheng-Yao

    2014-01-01

    This study uses the Joule heating effect-generated temperature difference to monitor in real-time and localize both compressive and tensile strains for the polymer substrates used in the roll-to-roll process. A serpentine gold (Au) line was patterned on a polyethylenenaphthalate (PEN) substrate to form the strain sensor based on thermoresistive behavior. This strain sensor was then subjected to either current or voltage to induce the Joule heating effect on the Au resistor. An infrared (IR) detector was used to monitor the strain-induced temperature difference on the Au and PEN surfaces and the minimal detectable bending radius was 0.9 mm with a gauge factor (GF) of 1.46. The proposed design eliminates the judgment ambiguity from conventional resistive strain sensors where resistance is the only physical quantity monitored. This study precisely and successfully indicated the local strain quantitatively and qualitatively with complete simulations and measurements. PMID:24803196

  8. Development of a continuous roll-to-roll processing system for mass production of plastic optical film

    NASA Astrophysics Data System (ADS)

    Chang, Chih-Yuan; Tsai, Meng-Hsun

    2015-12-01

    This paper reports a highly effective method for the mass production of large-area plastic optical films with a microlens array pattern based on a continuous roll-to-roll film extrusion and roller embossing process. In this study, a thin steel mold with a micro-circular hole array pattern is fabricated by photolithography and a wet chemical etching process. The thin steel mold was then wrapped onto a metal cylinder to form an embossing roller mold. During the roll-to-roll process operation, a thermoplastic raw material (polycarbonate grains) was put into the barrel of the plastic extruder with a flat T-die. Then, the molten polymer film was extruded and immediately pressed against the surface of the embossing roller mold. Under the proper processing conditions, the molten polymer will just partially fill the micro-circular holes of the mold and due to surface tension form a convex lens surface. A continuous plastic optical film with a microlens array pattern was obtained. Experiments are carried out to investigate the effect of plastic microlens formation on the roll-to-roll process. Finally, the geometrical and optical properties of the fabricated plastic optical film were measured and proved satisfactory. This technique shows great potential for the mass production of large-area plastic optical films with a microlens array pattern.

  9. Laser processing of organic photovoltaic cells with a roll-to-roll manufacturing process

    NASA Astrophysics Data System (ADS)

    Petsch, Tino; Haenel, Jens; Clair, Maurice; Keiper, Bernd; Scholz, Christian

    2011-03-01

    Flexible large area organic photovoltaic (OPV) is currently one of the fastest developing areas of organic electronics. New light absorbing polymer blends combined with new transparent conductive materials provide higher power conversion efficiencies while new and improved production methods are developed to achieve higher throughput at reduced cost. A typical OPV is formed by TCO layers as the transparent front contact and polymers as active layer as well as interface layer between active layer and front contact. The several materials have to be patterned in order to allow for a row connection of the solar cell. 3D-Micromac used ultra-short pulsed lasers to evaluate the applicability of various wavelengths for the selective ablation of the indium tin oxide (ITO) layer and the selective ablation of the bulk hetero junction (BHJ) consisting of poly(3-hexylthiophene):phenyl-C61-butyric acid methyl ester (P3HT:PCBM) on top of a Poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate) (PEDOT:PSS) without damaging the ITO. These lasers in combination with high performance galvanometer scanning systems achieve superior scribing quality without damaging the substrate. With scribing speeds of 10 m/s and up it is possible to integrate this technology into a roll-to-roll manufacturing tool. The functionality of an OPV usually also requires an annealing step, especially when using a BHJ for the active layer consisting of P3HT:PCBM, to optimize the layers structure and therewith the efficiency of the solar cell (typically by thermal treatment, e.g. oven). The process of laser annealing was investigated using a short-pulsed laser with a wavelength close to the absorption maximum of the BHJ.

  10. Roll-to-roll atomic layer deposition process for flexible electronics encapsulation applications

    SciTech Connect

    Maydannik, Philipp S. Kääriäinen, Tommi O.; Lahtinen, Kimmo; Cameron, David C.; Söderlund, Mikko; Soininen, Pekka; Johansson, Petri; Kuusipalo, Jurkka; Moro, Lorenza; Zeng, Xianghui

    2014-09-01

    At present flexible electronic devices are under extensive development and, among them, flexible organic light-emitting diode displays are the closest to a large market deployment. One of the remaining unsolved challenges is high throughput production of impermeable flexible transparent barrier layers that protect sensitive light-emitting materials against ambient moisture. The present studies deal with the adaptation of the atomic layer deposition (ALD) process to high-throughput roll-to-roll production using the spatial ALD concept. We report the development of such a process for the deposition of 20 nm thickness Al{sub 2}O{sub 3} diffusion barrier layers on 500 mm wide polymer webs. The process uses trimethylaluminum and water as precursors at a substrate temperature of 105 °C. The observation of self-limiting film growth behavior and uniformity of thickness confirms the ALD growth mechanism. Water vapor transmission rates for 20 nm Al{sub 2}O{sub 3} films deposited on polyethylene naphthalate (PEN) substrates were measured as a function of substrate residence time, that is, time of exposure of the substrate to one precursor zone. Moisture permeation levels measured at 38 °C/90% relative humidity by coulometric isostatic–isobaric method were below the detection limit of the instrument (<5 × 10{sup −4} g/m{sup 2} day) for films coated at web moving speed of 0.25 m/min. Measurements using the Ca test indicated water vapor transmission rates ∼5 × 10{sup −6} g/m{sup 2} day. Optical measurements on the coated web showed minimum transmission of 80% in the visible range that is the same as the original PEN substrate.

  11. Roll-to-roll cohesive, coated, flexible, high-efficiency polymer light-emitting diodes utilizing ITO-free polymer anodes.

    PubMed

    Shin, Seongbeom; Yang, Minyang; Guo, L Jay; Youn, Hongseok

    2013-12-01

    This paper reports solution-processed, high-efficiency polymer light-emitting diodes fabricated by a new type of roll-to-roll coating method under ambient air conditions. A noble roll-to-roll cohesive coating system utilizes only natural gravity and the surface tension of the solution to flow out from the capillary to the surface of the substrate. Because this mechanism uses a minimally cohesive solution, the roll-to-roll cohesive coating can effectively realize an ultra-thin film thickness for the electron injection layer. In addition, the roll-to-roll cohesive coating enables the fabrication of a thicker polymer anode film more than 250 nm at one time by modification of the surface energy and without wasting the solution. It is observed that the standard sheet resistance deviation of the polymer anode is only 2.32 Ω/□ over 50 000 bending cycles. The standard sheet resistance deviation of the polymer anode in the different bending angles (0 to 180°) is 0.313 Ω/□, but the case of the ITO-PET is 104.93 Ω/□. The average surface roughness of the polymer anode measured by atomic force microscopy is only 1.06 nm. Because the surface of the polymer anode has a better quality, the leakage current of the polymer light-emitting diodes (PLEDs) using the polymer anode is much lower than that using the ITO-PET substrate. The luminous power efficiency of the two devices is 4.13 lm/W for the polymer anode and 3.21 lm/W for the ITO-PET. Consequently, the PLEDs made by using the polymer anode exhibited 28% enhanced performance because the polymer anode represents not only a higher transparency than the ITO-PET in the wavelength of 560 nm but also greatly reduced roughness. The optimized the maximum current efficiency and power efficiency of the device show around 6.1 cd/A and 5.1 lm/W, respectively, which is comparable to the case of using the ITO-glass. PMID:23784859

  12. Develop Roll-to-Roll Manufacturing Process of ZrO2 Nanocrystals/Acrylic Nanocomposites for High Refractive Index Applications

    SciTech Connect

    Joshi, Pooran C.; Compton, Brett G.; Li, Jianlin; Jellison, Jr, Gerald Earle; Duty, Chad E; Chen, Zhiyun

    2015-04-01

    The purpose of this Cooperative Research and Development Agreement (CRADA) was to develop and evaluate ZrO2/acrylic nanocomposite coatings for integrated optoelectronic applications. The formulations engineered to be compatible with roll-to-roll process were evaluated in terms of optical and dielectric properties. The uniform distribution of the ZrO2 nanocrystals in the polymer matrix resulted in highly tunable refractive index and dielectric response suitable for advanced photonic and electronic device applications.

  13. In situ monitoring of structure formation in the active layer of polymer solar cells during roll-to-roll coating

    SciTech Connect

    Rossander, Lea H.; Zawacka, Natalia K.; Dam, Henrik F.; Krebs, Frederik C.; Andreasen, Jens W.

    2014-08-15

    The active layer crystallization during roll-to-roll coating of organic solar cells is studied in situ. We developed an X-ray setup where the coater unit is an integrated part of the small angle X-ray scattering instrument, making it possible to control the coating process while recording scattering measurements in situ, enabling us to follow the crystal formation during drying. By varying the distance between the coating head and the point where the X-ray beam hits the film, we obtained measurements of 4 different stages of drying. For each of those stages, the scattering from as long a foil as possible is summed together, with the distance from coating head to scattering point kept constant. The results are average crystallographic properties for the active layer coated on a 30 m long foil. With this insight into the dynamics of crystallization in a roll-coated polymer film, we find that the formation of textured and untextured crystallites seems uncorrelated, and happens at widely different rates. Untextured P3HT crystallites form later in the drying process than expected which may explain previous studies speculating that untextured crystallization depends on concentration. Textured crystallites, however, begin forming much earlier and steadily increases as the film dries, showing a development similar to other in situ studies of these materials.

  14. Roll-to-Roll Solution-Processible Small-Molecule OLEDs

    SciTech Connect

    Liu, Jie Jerry

    2012-07-31

    The objective of this program is to develop key knowledge and make critical connections between technologies needed to enable low-cost manufacturing of OLED lighting products. In particular, the program was intended to demonstrate the feasibility of making high performance Small-Molecule OLEDs (SM-OLED) using a roll-to-roll (R2R) wet-coating technique by addressing the following technical risks (1) Whether the wet-coating technique can provide high performance OLEDs, (2) Whether SM-OLED can be made in a R2R manner, (3) What are the requirements for coating equipment, and (4) Whether R2R OLEDs can have the same performance as the lab controls. The program has been managed and executed according to the Program Management Plan (PMP) that was first developed at the beginning of the program and further revised accordingly as the program progressed. Significant progress and risk reductions have been accomplished by the end of the program. Specific achievements include: (1) Demonstrated that wet-coating can provide OLEDs with high LPW and long lifetime; (2) Demonstrated R2R OLEDs can be as efficient as batch controls (Figure 1) (3) Developed & validated basic designs for key equipment necessary for R2R SM-OLEDs; (4) Developed know-hows & specifications on materials & ink formulations critical to wetcoating; (5) Developed key R2R processes for each OLED layer (6) Identified key materials and components such as flexible barrier substrates necessary for R2R OLEDs.

  15. Characterization of printed planar electromagnetic coils using digital extrusion and roll-to-roll flexographic processes

    NASA Astrophysics Data System (ADS)

    Rickard, Scott

    Electromagnets are a crucial component in a wide range of more complex electrical devices due to their ability to turn electrical energy into mechanical energy and vice versa. The trend for electronics becoming smaller and lighter has led to increased interest in using flat, planar electromagnetic coils, which have been shown to perform better at scaled down sizes. The two-dimensional geometry of a planar electromagnetic coil yields itself to be produced by a roll-to-roll additive manufacturing process. The emergence of the printed electronics field, which uses traditional printing processes to pattern functional inks, has led to new methods of mass-producing basic electrical components. The ability to print a planar electromagnetic coil using printed electronics could rival the traditional subtractive and semi-subtractive PCB process of manufacturing. The ability to print lightweight planar electromagnetic coils on flexible substrates could lead to their inclusion into intelligent packaging applications and could have specific use in actuating devices, transformers, and electromagnetic induction applications such as energy harvesting or wireless charging. In attempts to better understand the limitations of printing planar electromagnetic coils, the effect that the design parameters of the planar coils have on the achievable magnetic field strength were researched. A comparison between prototyping methods of digital extrusion and manufacturing scale flexographic printing are presented, discussing consistency in the printed coils and their performance in generating magnetic fields. A method to predict the performance of these planar coils is introduced to allow for design within required needs of an application. Results from the research include a demonstration of a printed coil being used in a flat speaker design, working off of actuating principles.

  16. Fabrication of microlens arrays on a glass substrate by roll-to-roll process with PDMS mold

    NASA Astrophysics Data System (ADS)

    Hu, Chia-Nying; Su, Guo-Dung J.

    2009-08-01

    This paper presents a roll-to-roll method to fabricate microlens arrays on a glass substrate by using a cost-effective PDMS (Polydimethylsiloxane) mold. We fabricated microlens arrays mold, which was made by photoresist(AZ4620), on the silicon substrate by thermal reflow process, and transferred the pattern to PDMS film. Roll-to-roll system is a standard printing process whose roller is made of acrylic cylinder surrounded with the PDMS mold. UV resin was chosen to be the material to make microlens in rolling process with UV light curing. We investigated the quality of microlens arrays by changing the parameters, such as embossing pressure and rolling speed, to ensure good quality of microlens arrays.

  17. Roll to Roll Electric Field "Z" Alignment of Nanoparticles from Polymer Solutions for Manufacturing Multifunctional Capacitor Films.

    PubMed

    Guo, Yuanhao; Batra, Saurabh; Chen, Yuwei; Wang, Enmin; Cakmak, Miko

    2016-07-20

    A roll to roll continuous processing method is developed for vertical alignment ("Z" alignment) of barium titanate (BaTiO3) nanoparticle columns in polystyrene (PS)/toluene solutions. This is accomplished by applying an electric field to a two-layer solution film cast on a carrier: one is the top sacrificial layer contacting the electrode and the second is the polymer solution dispersed with BaTiO3 particles. Flexible Teflon coated mesh is utilized as the top electrode that allows the evaporation of solvent through the openings. The kinetics of particle alignment and chain buckling is studied by the custom-built instrument measuring the real time optical light transmission during electric field application and drying steps. The nanoparticles dispersed in the composite bottom layer form chains due to dipole-dipole interaction under an applied electric field. In relatively weak electric fields, the particle chain axis tilts away from electric field direction due to bending caused by the shrinkage of the film during drying. The use of strong electric fields leads to maintenance of alignment of particle chains parallel to the electric field direction overcoming the compression effect. At the end of the process, the surface features of the top porous electrodes are imprinted at the top of the top sacrificial layer. By removing this layer a smooth surface film is obtained. The nanocomposite films with "Z" direction alignment of BaTiO3 particles show substantially increased dielectric permittivity in the thickness direction for enhancing the performance of capacitors. PMID:27322765

  18. Waveguide slot-excited long racetrack electron cyclotron resonance plasma source for roll-to-roll (scanning) processing

    SciTech Connect

    You, H.-J.

    2013-07-15

    We present a SLot-excited ANtenna (SLAN) long racetrack ECR plasma source that is utilized for roll-to-roll plasma processing such as thin film encapsulation of large-area OLED (organic light emitting diode) panel or modification of fabric surfaces. This source is designed to be long, and to operate under high density uniform plasma with sub-milli-torr pressures. The above features are accomplished by a slot-excited long racetrack resonator with a toroidal geometry of magnetic field ECR configuration, and reinforced microwave electric distributions along the central region of plasma chamber. Also, a new feature has been added to the source. This is to employ a tail plunger, which allows the microwave electric field and the uniformity of the plasma profile to be easily adjustable. We have successfully generated Ar plasmas operating with the microwave power of 0.5–3 kW in the pressure range of 0.2–10 mTorr. The plasma is uniform (<10%) in the direction of the straight track and has a Gaussian profile in the roll-to-roll (scanning) direction. In addition, it is shown that the tail plunger could adjust the plasma profile in order to obtain plasma uniformity. Furthermore, based on the results, we suggest a newly designed up-scaled racetrack-SLAN source.

  19. Bioinspired superhydrophobic surfaces, fabricated through simple and scalable roll-to-roll processing

    NASA Astrophysics Data System (ADS)

    Park, Sung-Hoon; Lee, Sangeui; Moreira, David; Bandaru, Prabhakar R.; Han, Intaek; Yun, Dong-Jin

    2015-10-01

    A simple, scalable, non-lithographic, technique for fabricating durable superhydrophobic (SH) surfaces, based on the fingering instabilities associated with non-Newtonian flow and shear tearing, has been developed. The high viscosity of the nanotube/elastomer paste has been exploited for the fabrication. The fabricated SH surfaces had the appearance of bristled shark skin and were robust with respect to mechanical forces. While flow instability is regarded as adverse to roll-coating processes for fabricating uniform films, we especially use the effect to create the SH surface. Along with their durability and self-cleaning capabilities, we have demonstrated drag reduction effects of the fabricated films through dynamic flow measurements.

  20. Bioinspired superhydrophobic surfaces, fabricated through simple and scalable roll-to-roll processing.

    PubMed

    Park, Sung-Hoon; Lee, Sangeui; Moreira, David; Bandaru, Prabhakar R; Han, InTaek; Yun, Dong-Jin

    2015-01-01

    A simple, scalable, non-lithographic, technique for fabricating durable superhydrophobic (SH) surfaces, based on the fingering instabilities associated with non-Newtonian flow and shear tearing, has been developed. The high viscosity of the nanotube/elastomer paste has been exploited for the fabrication. The fabricated SH surfaces had the appearance of bristled shark skin and were robust with respect to mechanical forces. While flow instability is regarded as adverse to roll-coating processes for fabricating uniform films, we especially use the effect to create the SH surface. Along with their durability and self-cleaning capabilities, we have demonstrated drag reduction effects of the fabricated films through dynamic flow measurements. PMID:26490133

  1. Bioinspired superhydrophobic surfaces, fabricated through simple and scalable roll-to-roll processing

    PubMed Central

    Park, Sung-Hoon; Lee, Sangeui; Moreira, David; Bandaru, Prabhakar R.; Han, InTaek; Yun, Dong-Jin

    2015-01-01

    A simple, scalable, non-lithographic, technique for fabricating durable superhydrophobic (SH) surfaces, based on the fingering instabilities associated with non-Newtonian flow and shear tearing, has been developed. The high viscosity of the nanotube/elastomer paste has been exploited for the fabrication. The fabricated SH surfaces had the appearance of bristled shark skin and were robust with respect to mechanical forces. While flow instability is regarded as adverse to roll-coating processes for fabricating uniform films, we especially use the effect to create the SH surface. Along with their durability and self-cleaning capabilities, we have demonstrated drag reduction effects of the fabricated films through dynamic flow measurements. PMID:26490133

  2. Low-temperature roll-to-roll coating procedure of dye-sensitized solar cell photoelectrodes on flexible polymer-based substrates

    NASA Astrophysics Data System (ADS)

    Tinguely, Jean-Claude; Solarska, Renata; Braun, Artur; Graule, Thomas

    2011-04-01

    A new approach for the large-scale production of flexible photoelectrodes for dye-sensitized solar cells (DSSCs) is presented by roll-to-roll coating of a titanium dioxide nanodispersion containing the block copolymer 'Pluronic®' (PEOx-PPOy-PEOx, PEO: poly(ethylene oxide), PPO: poly(propylene oxide)). Functional DSSCs were assembled and the different coating procedures compared with respect to their solar power conversion efficiency. It is shown that the binder 'Pluronic' can be removed at processing temperatures as low as 140 °C, thus aiding achievement of sufficient adhesion to the ITO-PET support, higher porosity of the TiO2 layer and decreased crack appearance. Further optimization of this method is particularly promising when combined with other known low-temperature methods.

  3. Morphology-insensitive Performance Facilitates Transition from Spin-Coating to Roll-to-Roll Coating For High-Performance, Solution-Processed Solar Cells

    NASA Astrophysics Data System (ADS)

    Delongchamp, Dean

    Solution processing via roll-to-roll (R2R) coating promises a low cost, low thermal-budget, sustainable revolution for the production of solar cells. Yet virtually all high efficiency solution processed research cells have been demonstrated by spin-coating, a low-volume deposition process. We present detailed device and morphology studies of an organic photovoltaic (OPV) system deposited by a high volume manufacturing technique, blade-coating, that achieves greater than 9.5 % power conversion efficiency (PCE). The average crystal domain orientation and characteristic phase separation length distribution are markedly different when deposited by blade-coating rather than spin-coating,. This result allows us to determine which aspects of morphology are not relevant to the PCE of this system. Whether the crystallites are ``face on'' or ``edge on'' does not appear to impact the PCE of system, nor does the length scale or ``hierarchical'' nature of the phase length scale. Persistent morphological qualities that may be associated with high PCE in this system are relatively pure phases and relatively strong diffraction. We posit that OPV systems in which the PCE is less sensitive to morphology may also be less sensitive to film thickness, enabling some to maintain high PCE in active layers thicker than greater than ~200 nm. We confirm that blade-coating is a suitable prototyping technique for R2R coating by demonstrating nominally identical morphologies for both piece blade-coating and continuous-web, slot-die coating.

  4. Ultrashort-pulsed laser processing and solution based coating in roll-to-roll manufacturing of organic photovoltaics

    NASA Astrophysics Data System (ADS)

    Hördemann, C.; Hirschfelder, K.; Schaefer, M.; Gillner, A.

    2015-09-01

    The breakthrough of flexible organic electronics and especially organic photovoltaics is highly dependent on cost-efficient production technologies. Roll-2-Roll processes show potential for a promising solution in terms of high throughput and low-cost production of thin film organic components. Solution based material deposition and integrated laser patterning processes offer new possibilities for versatile production lines. The use of flexible polymeric substrates brings along challenges in laser patterning which have to be overcome. One main challenge when patterning transparent conductive layers on polymeric substrates are material bulges at the edges of the ablated area. Bulges can lead to short circuits in the layer system leading to device failure. Therefore following layers have to have a sufficient thickness to cover and smooth the ridge. In order to minimize the bulging height, a study has been carried out on transparent conductive ITO layers on flexible PET substrates. Ablation results using different beam shapes, such as Gaussian beam, Top-Hat beam and Donut-shaped beam, as well as multi-pass scribing and double-pulsed ablation are compared. Furthermore, lab scale methods for cleaning the patterned layer and eliminating bulges are contrasted to the use of additional water based sacrificial layers in order to obtain an alternative procedure suitable for large scale Roll-2-Roll manufacturing. Besides progress in research, ongoing transfer of laser processes into a Roll-2-Roll demonstrator is illustrated. By using fixed optical elements in combination with a galvanometric scanner, scribing, variable patterning and edge deletion can be performed individually.

  5. High-rate, roll-to-roll nanomanufacturing of flexible systems

    NASA Astrophysics Data System (ADS)

    Cooper, Khershed P.; Wachter, Ralph F.

    2012-10-01

    Since the National Nanotechnology Initiative was first announced in 2000, nanotechnology has developed an impressive catalog of nano-scale structures with building-blocks such as nanoparticles, nanotubes, nanorods, nanopillars, and quantum dots. Similarly, there are accompanying materials processes such as, atomic layer deposition, pulsed layer deposition, nanoprinting, nanoimprinting, transfer printing, nanolithography and nanopatterning. One of the challenges of nanomanufacturing is scaling up these processes reliably and affordably. Roll-to-roll manufacturing is a means for scaling up, for increasing throughput. It is high-speed production using a continuous, moving platform such as a web or a flexible substrate. The adoption of roll-to-roll to nanomanufacturing is novel. The goal is to build structures and devices with nano-scale features and specific functionality. The substrate could be a polymer, metal foil, silk, cloth or paper. The materials to build the structures and multi-level devices could be organic, inorganic or biological. Processing could be solution-based, e.g., ink-jet printing, or vacuum-based, e.g., chemical vapor deposition. Products could be electronics, optoelectronics, membranes, catalysts, microfluidics, lab-on-film, filters, etc. By this means, processing of large and conformal areas is achievable. High-throughput translates into low cost, which is the attraction of roll-to-roll nanomanufacturing. There are technical challenges requiring fundamental scientific advances in materials and process development and in manufacturing and system-integration where achieving nano-scale feature size, resolution and accuracy at high speeds can be major hurdles. We will give an overview of roll-to-roll nanomanufacturing with emphasis on the need to understand the material, process and system complexities, the need for instrumentation, measurement, and process control and describe the concept of cyber-enabled nanomanufacturing for reliable and

  6. Toward large-area roll-to-roll printed nanophotonic sensors

    NASA Astrophysics Data System (ADS)

    Karioja, Pentti; Hiltunen, Jussi; Aikio, Sanna M.; Alajoki, Teemu; Tuominen, Jarkko; Hiltunen, Marianne; Siitonen, Samuli; Kontturi, Ville; Böhlen, Karl; Hauser, Rene; Charlton, Martin; Boersma, Arjen; Lieberzeit, Peter; Felder, Thorsten; Eustace, David; Haskal, Eliav

    2014-05-01

    Polymers have become an important material group in fabricating discrete photonic components and integrated optical devices. This is due to their good properties: high optical transmittance, versatile processability at relative low temperatures and potential for low-cost production. Recently, nanoimprinting or nanoimprint lithography (NIL) has obtained a plenty of research interest. In NIL, a mould is pressed against a substrate coated with a moldable material. After deformation of the material, the mold is separated and a replica of the mold is formed. Compared with conventional lithographic methods, imprinting is simple to carry out, requires less-complicated equipment and can provide high-resolution with high throughput. Nanoimprint lithography has shown potential to become a method for low-cost and high-throughput fabrication of nanostructures. We show the development process of nano-structured, large-area multi-parameter sensors using Photonic Crystal (PC) and Surface Enhanced Raman Scattering (SERS) methodologies for environmental and pharmaceutical applications. We address these challenges by developing roll-to-roll (R2R) UV-nanoimprint fabrication methods. Our development steps are the following: Firstly, the proof of concept structures are fabricated by the use of wafer-level processes in Si-based materials. Secondly, the master molds of successful designs are fabricated, and they are used to transfer the nanophotonic structures into polymer materials using sheet-level UV-nanoimprinting. Thirdly, the sheet-level nanoimprinting processes are transferred to roll-to-roll fabrication. In order to enhance roll-to-roll manufacturing capabilities, silicone-based polymer material development was carried out. In the different development phases, Photonic Crystal and SERS sensor structures with increasing complexities were fabricated using polymer materials in order to enhance sheet-level and roll-to-roll manufacturing processes. In addition, chemical and molecular

  7. Roll-to-roll manufacturing of electronic devices

    NASA Astrophysics Data System (ADS)

    Morrison, N. A.; Stolley, T.; Hermanns, U.; Kroemer, U.; Reus, A.; Lopp, A.; Campo, M.; Landgraf, H.

    2012-03-01

    Roll-to-Roll (R2R) production of thin film based electronic devices (e.g. solar cells, activematrix TFT backplanes & touch screens) combine the advantages of the use of inexpensive, lightweight & flexible substrates with high throughput production. Significant cost reduction opportunities can also be found in terms of processing tool capital cost, utilized substrate area and process gas flow when compared with batch processing systems. Nevertheless, material handling, device patterning and yield issues have limited widespread utilization of R2R manufacturing within the electronics industry.

  8. Laser direct write system for fabricating seamless roll-to-roll lithography tools

    NASA Astrophysics Data System (ADS)

    Petrzelka, Joseph E.; Hardt, David E.

    2013-03-01

    Implementations of roll to roll contact lithography require new approaches towards manufacturing tooling, including stamps for roll to roll nanoimprint lithography (NIL) and soft lithography. Suitable roll based tools must have seamless micro- or nano-scale patterns and must be scalable to roll widths of one meter. The authors have developed a new centrifugal stamp casting process that can produce uniform cylindrical polymer stamps in a scalable manner. The pattern on the resulting polymer tool is replicated against a corresponding master pattern on the inner diameter of a centrifuge drum. This master pattern is created in photoresist using a UV laser direct write system. This paper discusses the design and implementation of a laser direct write system targeting the internal diameter of a rotating drum. The design uses flying optics to focus a laser beam along the axis of the centrifuge drum and to redirect the beam towards the drum surface. Experimental patterning results show uniform coatings of negative photoresist in the centrifuge drum that are effectively patterned with a 405 nm laser diode. Seamless patterns are shown to be replicated in a 50 mm diameter, 60 mm long cylindrical stamp made from polydimethylsiloxane (PDMS). Direct write results show gratings with line widths of 10 microns in negative photoresist. Using an FPGA, the laser can be accurately timed against the centrifuge encoder to create complex patterns.

  9. Roll-to-Roll Nanoimprint Lithography Simulations for Flexible Substrates

    NASA Astrophysics Data System (ADS)

    Spann, Andrew; Jain, Akhilesh; Bonnecaze, Roger

    2015-11-01

    UV roll-to-roll nanoimprint lithography enables the patterning of features onto a flexible substrate for bendable electronics in a continuous process. One of the most important design goals in this process is to make the residual layer thickness of the photoresist in unpatterned regions as thin and uniform as possible. Another important goal is to minimize the imprint time to maximize throughput. We develop a multi-scale model to simulate the spreading of photoresist drops as the template is pressed against the substrate. We include the effect of capillary pressure on the bending of the substrate and show how this distorts uniformity in the residual thickness layer. Our simulation code is parallelized and can simulate the flow and merging of thousands of drops. We investigate the effect of substrate tension and the initial arrangement of drops on the residual layer thickness and imprint time. We find that for a given volume of photoresist, distributing that volume to more drops initially decreases the imprint time. We conclude with recommendations for scale-up and optimal operations of roll-to-roll nanoimprint lithography systems. The authors acknowledge the Texas Advanced Computing Center at The University of Texas at Austin for providing high performance computing resources.

  10. A review of roll-to-roll nanoimprint lithography

    PubMed Central

    2014-01-01

    Since its introduction in 1995, nanoimprint lithography has been demonstrated in many researches as a simple, low-cost, and high-throughput process for replicating micro- and nanoscale patterns. Due to its advantages, the nanoimprint lithography method has been rapidly developed over the years as a promising alternative to conventional nanolithography processes to fulfill the demands generated from the recent developments in the semiconductor and flexible electronics industries, which results in variations of the process. Roll-to-roll (R2R) nanoimprint lithography (NIL) is the most demanded technique due to its high-throughput fulfilling industrial-scale application. In the present work, a general literature review on the various types of nanoimprint lithography processes especially R2R NIL and the methods commonly adapted to fabricate imprint molds are presented to provide a clear view and understanding on the nanoimprint lithography technique as well as its recent developments. PACS 81.16.Nd PMID:25024682

  11. High speed electrical measurement for roll-to-roll nanomanufacturing

    NASA Astrophysics Data System (ADS)

    Orloff, Nathan; Long, Christian; Obrzut, Jan; Maillaud, Laurent; Mirri, Francesca; Kole, Thomas; McMichael, Robert; Pasquali, Matteo; Stranick, Stephan; Liddle, J. Alexander

    2015-03-01

    Roll-to-roll processing of nanomaterials can produce high-quality coatings and filaments continuously, enabling materials applications for electronics, fabrics, and wires. These applications often require specific electrical properties that are correlated to the material's nanostructure. While several high-throughput structural characterizations techniques exist, there are relatively few contactless options for quantifying the electrical properties of materials for nanomanufacturing. Here, we demonstrate a microwave method for measuring complex permittivity (or geometry for samples of known dielectric properties) in a millisecond. The demonstrated measurement times are suitable for current industrial needs, allowing real-time materials characterization and in-line control of processing variables without disrupting production. Address correspondence to Dr. Stephan J. Stranick, and Dr. J. Alexander Liddle.

  12. Tolerance of Three-Stage CIGS Deposition to Variations Imposed by Roll-to-Roll Processing: Final Technical Report, May 2003 - September 2005

    SciTech Connect

    Beck, M. E.; Britt, J. S.

    2006-01-01

    Three-stage co-evaporation of CIGS imposes stringent limits on the parameter space if high-efficient devices are to result. Substrate temperatures during the 1st stage (as well as during the 2nd and 3rd stage), Se partial pressure, and amount of Na supplied are critical for good nucleation, proper In-Ga-selenide precursor phase, and diffusion of Cu into the precursor, as well as diffusion of Ga through the film. In addition, the degree of Cu-rich excursion impacts maximum performance and process tolerance. Enveloping the above is the basic time-temperature profile inextricably linked to the metals delivery rates. Although high-efficiency, three-stage deposited CIGS devices on the R&D scale are grown at about 20-45 minutes to thicknesses of 2 to 2.5 m, the latter is not a viable approach for an economic manufacturing process. At Global Solar Energy, Inc., CIGS films are typically grown in about 6 minutes to thicknesses of less than 2 m. At the same time, the emissivity and thermal conductivity of stainless steel is vastly different from that of glass, and the reduced growth time poses restrictions on the substrate temperature ramp rates and diffusion of species (reaction kinetics). Material compatibility in the highly corrosive Se environment places limitations on the substrate heaters; i.e., substrate temperatures. Finally, one key advantage of a RTR deposition approach (compact equipment) restricts post CIGS Se exposure and cool-down rates to be vastly different than those practiced in the laboratory.

  13. Roll-to-Roll production of carbon nanotubes based supercapacitors

    NASA Astrophysics Data System (ADS)

    Zhu, Jingyi; Childress, Anthony; Karakaya, Mehmet; Roberts, Mark; Arcilla-Velez, Margarita; Podila, Ramakrishna; Rao, Apparao

    2014-03-01

    Carbon nanomaterials provide an excellent platform for electrochemical double layer capacitors (EDLCs). However, current industrial methods for producing carbon nanotubes are expensive and thereby increase the costs of energy storage to more than 10 Wh/kg. In this regard, we developed a facile roll-to-roll production technology for scalable manufacturing of multi-walled carbon nanotubes (MWNTs) with variable density on run-of-the-mill kitchen Al foils. Our method produces MWNTs with diameter (heights) between 50-100 nm (10-100 μm), and a specific capacitance as high as ~ 100 F/g in non-aqueous electrolytes. In this talk, the fundamental challenges involved in EDLC-suitable MWNT growth, roll-to-roll production, and device manufacturing will be discussed along with electrochemical characteristics of roll-to-roll MWNTs. Research supported by NSF CMMI Grant1246800.

  14. High resolution patterning for flexible electronics via roll-to-roll nanoimprint lithography

    NASA Astrophysics Data System (ADS)

    Sabik, Sami; de Riet, Joris; Yakimets, Iryna; Smits, Edsger

    2014-03-01

    Flexible electronics is a growing field and is currently maturing in applications such as displays, smart packaging, organic light-emitting diodes and organic photovoltaic cells. In order to process on flexible substrates at high throughput and large areas, novel patterning techniques will be essential. Conventional optical lithography is limited in throughput as well as resolution, and requires several alignment steps to generate multi-layered patterns, required for applications such as thin-film transistors. It therefore remains a complex and expensive process. Nanoimprint lithography is an emerging alternative to optical lithography, demonstrating patterning capabilities over a wide range of resolutions, from several microns down to a few nanometres. For display applications, nanoimprint lithography can be used to pattern various layers. Micron sized thin-film transistors for backplane can be fabricated where a self-aligned geometry is used to decrease the number of alignment steps, and increase the overlay accuracy. In addition, nano-structures can be used for optical applications such as anti-reflective surfaces and nano patterned transparent electrodes. Imprint lithography is a fully roll-to-roll compatible process and enables large area and high throughput fabrication for flexible electronics. In this paper we discuss the possibilities and the challenges of large area patterning by roll-to-roll nanoimprint lithography, reviewing micron and nano sized structures realized on our roll-to-roll equipment. Nano patterned transparent electrodes, moth-eye antireflective coatings, and multilevel structures will be covered.

  15. Towards roll-to-roll fabrication of electronics, optics, and optoelectronics for smart and intelligent packaging

    NASA Astrophysics Data System (ADS)

    Kololuoma, Terho K.; Tuomikoski, Markus; Makela, Tapio; Heilmann, Jali; Haring, Tomi; Kallioinen, Jani; Hagberg, Juha; Kettunen, Ilkka; Kopola, Harri K.

    2004-06-01

    Embedding of optoelectrical, optical, and electrical functionalities into low-cost products like packages and printed matter can be used to increase their information content. These functionalities make also possible the realization of new type of entertaining, impressive or guiding effects on the product packages and printed matter. For these purposes, components like displays, photodetectors, light sources, solar cells, battery elements, diffractive optical elements, lightguides, electrical conductors, resistors, transistors, switching elements etc. and their integration to functional modules are required. Additionally, the price of the components for low-end products has to be in cent scale or preferably below that. Therefore, new, cost-effective, and volume scale capable manufacturing techniques are required. Recent developments of liquid-phase processable electrical and optical polymeric, inorganic, and hybrid materials - inks - have made it possible to fabricate functional electrical, optical and optoelectrical components by conventional roll-to-roll techniques such as gravure printing, embossing, digital printing, offset, and screen printing on flexible paper and plastic like substrates. In this paper, we show our current achievements in the field of roll-to-roll fabricated, optics, electronics and optoelectronics. With few examples, we also demonstrate the printing and hot-embossing capabilities of table scale printing machines and VTT Electronic's 'PICO' roll-to-roll pilot production facility.

  16. Roll-to-Roll Nanomanufacturing of Hybrid Nanostructures for Energy Storage Device Design.

    PubMed

    Oakes, Landon; Hanken, Trevor; Carter, Rachel; Yates, William; Pint, Cary L

    2015-07-01

    A key limitation to the practical incorporation of nanostructured materials into emerging applications is the challenge of achieving low-cost, high throughput, and highly replicable scalable nanomanufacturing techniques to produce functional materials. Here, we report a benchtop roll-to-roll technique that builds upon the use of binary solutions of nanomaterials and liquid electrophoretic assembly to rapidly construct hybrid materials for battery design applications. We demonstrate surfactant-free hybrid mixtures of carbon nanotubes, silicon nanoparticles, MoS2 nanosheets, carbon nanohorns, and graphene nanoplatelets. Roll-to-roll electrophoretic assembly from these solutions enables the controlled fabrication of homogeneous coatings of these nanostructures that maintain chemical and physical properties defined by the synergistic combination of nanomaterials utilized without adverse effects of surfactants or impurities that typically limit liquid nanomanufacturing routes. To demonstrate the utility of this nanomanufacturing approach, we employed roll-to-roll electrophoretic processing to fabricate both positive and negative electrodes for lithium ion batteries in less than 30 s. The optimized full-cell battery, containing active materials of prelithiated silicon nanoparticles and MoS2 nanosheets, was assessed to exhibit energy densities of 167 Wh/kgcell(-1) and power densities of 9.6 kW/kgcell(-1). PMID:26053115

  17. Development of a paper based roll-to-roll nanoimprinting machine

    NASA Astrophysics Data System (ADS)

    Son, Byungwook

    Nanoimprint lithography (NIL) has been developed and studied since 1995. It is a technique where micro- or nanoscale patterns are transferred to soft materials such as polymer through pressing a stamp with certain patterns into this materials and then solidifying it by cooling at lower temperature or curing under ultra violet excitement. High Cost and low throughput of batch mode nanoimprint lithography (NIL) processes are limiting its wide range of applications in meeting industry manufacturing requirements. The roll-to-roll (R2R) nanoimprinting technology is emerged as a solution to this issue. This thesis study presents the design, build and test of an innovative R2R T-NIL process machine for nanofabrication and MEMS fabrication applications, which consists of individual modules of heating, inking, pressuring, and rotational speed control. The system utilizes PDMS as mold material, PMMA as imprinting material, and paper as substrate material. In order to achieve a uniform pressure on PMMA during imprinting process, an innovative air pressure device (APD) was developed and integrated with R2R machine. The APD replaces the conventional 2-roll line contact pressure approach and can cover one third of the surface of the imprinting roller with a uniform pressure (1-3 psi). During the imprinting experiment, a mixture of PMMA (20w %) and 2-Ethoxyethyl acetate is applied on the paper substrate by an inking roller using capillary force and an IR heater is used for pre-heating and drying of polymer layers before it is fed into the imprinting module. Two 500-Watt cartridge heaters are installed on the roller and provide the heat to raise the PMMA film temperature during the imprinting.

  18. Planarization coating for polyimide substrates used in roll-to-roll fabrication of active matrix backplanes for flexible displays

    NASA Astrophysics Data System (ADS)

    Almanza-Workman, A. Marcia; Jeans, Albert; Braymen, Steve; Elder, Richard E.; Garcia, Robert A.; de la Fuente Vornbrock, Alejandro; Hauschildt, Jason; Holland, Edward; Jackson, Warren; Jam, Mehrban; Jeffrey, Frank; Junge, Kelly; Kim, Han-Jun; Kwon, Ohseung; Larson, Don; Luo, Hao; Maltabes, John; Mei, Ping; Perlov, Craig; Smith, Mark; Stieler, Dan; Taussig, Carl P.; Trovinger, Steve; Zhao, Lihua

    2012-03-01

    Good surface quality of plastic substrates is essential to reduce pixel defects during roll-to-roll fabrication of flexible display active matrix backplanes. Standard polyimide substrates have a high density of "bumps" from fillers and belt marks and other defects from dust and surface scratching. Some of these defects could be the source of shunts in dielectrics. The gate dielectric must prevent shorts between the source/drain and the gate in the transistors, resist shorts in the hold capacitor and stop shorts in the data/gate line crossovers in active matrix backplanes fabricated by self-aligned imprint lithography (SAIL) roll-to-roll processes. Otherwise data and gate lines will become shorted creating line or pixel defects. In this paper, we discuss the development of a proprietary UV curable planarization material that can be coated by roll-to-roll processes. This material was engineered to have low shrinkage, excellent adhesion to polyimide, high dry etch resistance, and great chemical and thermal stability. Results from PECVD deposition of an amorphous silicon stack on the planarized polyimide and compatibility with roll-to-roll processes to fabricate active matrix backplanes are also discussed. The effect of the planarization on defects in the stack, shunts in the dielectric and curvature of finished arrays will also be described.

  19. Hot embossing holographic images in BOPP shrink films through large-area roll-to-roll nanoimprint lithography

    NASA Astrophysics Data System (ADS)

    Jiang, Menglin; Lin, Shiwei; Jiang, Wenkai; Pan, Nengqian

    2014-08-01

    Diffraction grating-based holographic images have been successfully replicated in biaxially oriented polypropylene (BOPP) shrink films through large-area roll-to-roll nanoimprint technique. Such hot embossing of holographic images on BOPP films represents a promising means of creating novel security features in packaging applications. The major limitation of the high-quality replication is the relatively large thermal shrinkage of BOPP shrink film. However, although an appropriate shrinkage is demanded after embossing, over-shrinking not only causes distortion in embossed images, but also reduces the various properties of BOPP shrink films mainly due to the disappearance of orientation. The effects of embossing temperature on the mechanical, thermal and optical properties as well as polymer surface morphologies were systematically analyzed. The results show that the optimal process parameters are listed as follows: the embossing temperature at 104-110 °C, embossing force 6 kg/cm2 and film speed 32 m/min. The variation in flow behavior of polymer surface during hot embossing process is highly dependent on the temperature. In addition, the adhesion from the direct contact between the rubber press roller and polymer surfaces is suggested to cause the serious optical properties failure.

  20. Continuous roll-to-roll serpentine deposition for high throughput a-Si PV manufacturing

    SciTech Connect

    Izu, M.; Ovshinsky, H.C.; Deng, X.; Krisko, A.J.; Narasimhan, K.L.; Crucet, R.; Laarman, T.; Myatt, A.; Ovshinsky, S.R.

    1994-12-31

    In order to further improve the economies of scale which are inherent in ECD`s continuous roll-to-roll amorphous silicon alloy solar cell manufacturing process, the authors have developed a concept for a serpentine web plasma CVD deposition process to maximize throughput while keeping the size of the deposition chambers small. When this technique is incorporated into a continuous roll-to-roll PV manufacturing process, it will maximize the throughput for a high volume production plant, reduce the machine cost, improve gas utilization, reduce power consumption, and improve the solar cell stability. To demonstrate the serpentine web deposition concept, the authors have constructed a single loop serpentine deposition chamber to deposit a-Si for n-i-p structure solar cells. During the initial process of optimization, they have produced single-junction a-Si solar cells with 8.6% efficiency, and triple-junction a-Si solar cells with a 9.5% initial efficiency, where the top cell intrinsic layer was deposited in the serpentine deposition chamber.

  1. High-speed roll-to-roll manufacturing of graphene using a concentric tube CVD reactor

    PubMed Central

    Polsen, Erik S.; McNerny, Daniel Q.; Viswanath, B.; Pattinson, Sebastian W.; John Hart, A.

    2015-01-01

    We present the design of a concentric tube (CT) reactor for roll-to-roll chemical vapor deposition (CVD) on flexible substrates, and its application to continuous production of graphene on copper foil. In the CTCVD reactor, the thin foil substrate is helically wrapped around the inner tube, and translates through the gap between the concentric tubes. We use a bench-scale prototype machine to synthesize graphene on copper substrates at translation speeds varying from 25 mm/min to 500 mm/min, and investigate the influence of process parameters on the uniformity and coverage of graphene on a continuously moving foil. At lower speeds, high-quality monolayer graphene is formed; at higher speeds, rapid nucleation of small graphene domains is observed, yet coalescence is prevented by the limited residence time in the CTCVD system. We show that a smooth isothermal transition between the reducing and carbon-containing atmospheres, enabled by injection of the carbon feedstock via radial holes in the inner tube, is essential to high-quality roll-to-roll graphene CVD. We discuss how the foil quality and microstructure limit the uniformity of graphene over macroscopic dimensions. We conclude by discussing means of scaling and reconfiguring the CTCVD design based on general requirements for 2-D materials manufacturing. PMID:25997124

  2. High-speed roll-to-roll manufacturing of graphene using a concentric tube CVD reactor

    NASA Astrophysics Data System (ADS)

    Polsen, Erik S.; McNerny, Daniel Q.; Viswanath, B.; Pattinson, Sebastian W.; John Hart, A.

    2015-05-01

    We present the design of a concentric tube (CT) reactor for roll-to-roll chemical vapor deposition (CVD) on flexible substrates, and its application to continuous production of graphene on copper foil. In the CTCVD reactor, the thin foil substrate is helically wrapped around the inner tube, and translates through the gap between the concentric tubes. We use a bench-scale prototype machine to synthesize graphene on copper substrates at translation speeds varying from 25 mm/min to 500 mm/min, and investigate the influence of process parameters on the uniformity and coverage of graphene on a continuously moving foil. At lower speeds, high-quality monolayer graphene is formed; at higher speeds, rapid nucleation of small graphene domains is observed, yet coalescence is prevented by the limited residence time in the CTCVD system. We show that a smooth isothermal transition between the reducing and carbon-containing atmospheres, enabled by injection of the carbon feedstock via radial holes in the inner tube, is essential to high-quality roll-to-roll graphene CVD. We discuss how the foil quality and microstructure limit the uniformity of graphene over macroscopic dimensions. We conclude by discussing means of scaling and reconfiguring the CTCVD design based on general requirements for 2-D materials manufacturing.

  3. High-speed roll-to-roll manufacturing of graphene using a concentric tube CVD reactor.

    PubMed

    Polsen, Erik S; McNerny, Daniel Q; Viswanath, B; Pattinson, Sebastian W; John Hart, A

    2015-01-01

    We present the design of a concentric tube (CT) reactor for roll-to-roll chemical vapor deposition (CVD) on flexible substrates, and its application to continuous production of graphene on copper foil. In the CTCVD reactor, the thin foil substrate is helically wrapped around the inner tube, and translates through the gap between the concentric tubes. We use a bench-scale prototype machine to synthesize graphene on copper substrates at translation speeds varying from 25 mm/min to 500 mm/min, and investigate the influence of process parameters on the uniformity and coverage of graphene on a continuously moving foil. At lower speeds, high-quality monolayer graphene is formed; at higher speeds, rapid nucleation of small graphene domains is observed, yet coalescence is prevented by the limited residence time in the CTCVD system. We show that a smooth isothermal transition between the reducing and carbon-containing atmospheres, enabled by injection of the carbon feedstock via radial holes in the inner tube, is essential to high-quality roll-to-roll graphene CVD. We discuss how the foil quality and microstructure limit the uniformity of graphene over macroscopic dimensions. We conclude by discussing means of scaling and reconfiguring the CTCVD design based on general requirements for 2-D materials manufacturing. PMID:25997124

  4. Multilength Scale Patterning of Functional Layers by Roll-to-Roll Ultraviolet-Light-Assisted Nanoimprint Lithography.

    PubMed

    Leitgeb, Markus; Nees, Dieter; Ruttloff, Stephan; Palfinger, Ursula; Götz, Johannes; Liska, Robert; Belegratis, Maria R; Stadlober, Barbara

    2016-05-24

    Top-down fabrication of nanostructures with high throughput is still a challenge. We demonstrate the fast (>10 m/min) and continuous fabrication of multilength scale structures by roll-to-roll UV-nanoimprint lithography on a 250 mm wide web. The large-area nanopatterning is enabled by a multicomponent UV-curable resist system (JRcure) with viscous, mechanical, and surface properties that are tunable over a wide range to either allow for usage as polymer stamp material or as imprint resist. The adjustable elasticity and surface chemistry of the resist system enable multistep self-replication of structured resist layers. Decisive for defect-free UV-nanoimprinting in roll-to-roll is the minimization of the surface energies of stamp and resist, and the stepwise reduction of the stiffness from one layer to the next is essential for optimizing the reproduction fidelity especially for nanoscale features. Accordingly, we demonstrate the continuous replication of 3D nanostructures and the high-throughput fabrication of multilength scale resist structures resulting in flexible polyethylenetherephtalate film rolls with superhydrophobic properties. Moreover, a water-soluble UV-imprint resist (JRlift) is introduced that enables residue-free nanoimprinting in roll-to-roll. Thereby we could demonstrate high-throughput fabrication of metallic patterns with only 200 nm line width. PMID:27023664

  5. Roll-to-Roll Transfer of Electrospun Nanofiber Film for High-Efficiency Transparent Air Filter.

    PubMed

    Xu, Jinwei; Liu, Chong; Hsu, Po-Chun; Liu, Kai; Zhang, Rufan; Liu, Yayuan; Cui, Yi

    2016-02-10

    Particulate matter (PM) pollution in air has become a serious environmental issue calling for new type of filter technologies. Recently, we have demonstrated a highly efficient air filter by direct electrospinning of polymer fibers onto supporting mesh although its throughput is limited. Here, we demonstrate a high throughput method based on fast transfer of electrospun nanofiber film from roughed metal foil to a receiving mesh substrate. Compared with the direct electrospinning method, the transfer method is 10 times faster and has better filtration performance at the same transmittance, owing to the uniformity of transferred nanofiber film (>99.97% removal of PM2.5 at ∼73% of transmittance). With these advantages, large area freestanding nanofiber film and roll-to-roll production of air filter are demonstrated. PMID:26789781

  6. Comparison of roll-to-roll replication approaches for microfluidic and optical functions in lab-on-a-chip diagnostic devices

    NASA Astrophysics Data System (ADS)

    Brecher, Christian; Baum, Christoph; Bastuck, Thomas

    2015-03-01

    Economically advantageous microfabrication technologies for lab-on-a-chip diagnostic devices substituting commonly used glass etching or injection molding processes are one of the key enablers for the emerging market of microfluidic devices. On-site detection in fields of life sciences, point of care diagnostics and environmental analysis requires compact, disposable and highly functionalized systems. Roll-to-roll production as a high volume process has become the emerging fabrication technology for integrated, complex high technology products within recent years (e.g. fuel cells). Differently functionalized polymer films enable researchers to create a new generation of lab-on-a-chip devices by combining electronic, microfluidic and optical functions in multilayer architecture. For replication of microfluidic and optical functions via roll-to-roll production process competitive approaches are available. One of them is to imprint fluidic channels and optical structures of micro- or nanometer scale from embossing rollers into ultraviolet (UV) curable lacquers on polymer substrates. Depending on dimension, shape and quantity of those structures there are alternative manufacturing technologies for the embossing roller. Ultra-precise diamond turning, electroforming or casting polymer materials are used either for direct structuring or manufacturing of roller sleeves. Mastering methods are selected for application considering replication quality required and structure complexity. Criteria for the replication quality are surface roughness and contour accuracy. Structure complexity is evaluated by shapes producible (e.g. linear, circular) and aspect ratio. Costs for the mastering process and structure lifetime are major cost factors. The alternative replication approaches are introduced and analyzed corresponding to the criteria presented. Advantages and drawbacks of each technology are discussed and exemplary applications are presented.

  7. Mechanism of forming defects in roll-to-roll hot embossing of micro-pyramid arrays I: experiments

    NASA Astrophysics Data System (ADS)

    Yi, Peiyun; Shu, Yunyi; Deng, Yujun; Peng, Linfa; Lai, Xinmin

    2015-10-01

    Roll-to-roll (R2R) hot embossing is a promising process for the continuous fabrication of micro-structures on polymers with high accuracy and high throughput. This paper presents an experimental investigation into forming defects for micro-pyramid arrays during the R2R hot embossing process, aiming at a comprehensive understanding of the mechanism of forming defects as well as providing effective guidance for large-area fabrication of micro-structures on polymers. Four defect modes, the platform-like defect, the collapse-like defect, the high-low defect, and the bubble-like defect, have been discovered so far and the corresponding assessment methods have also been preliminarily established using Polypropylene (PP) as an example. The influence of two key process parameters including mold temperature and feeding speed on forming defects have been systematically investigated as well. It is demonstrated that the forming defects change from a platform-like defect to a collapse-like defect, then to a high-low defect, and finally disappear as the mold temperature increases. In the meantime, a bubble-like defect may occur if the feeding speed exceeds 1.2 m min-1. Besides, the forming defects are also observed in the R2R hot embossing of other polymer materials, such as poly(vinyl chloride), polymethyl-methacrylate and polycarbonate. Analysis of the mechanism of forming defects is beneficial to the understanding of the flow behavior in the R2R hot embossing process and to the realization of process control for high-accuracy replication of large-area polymer films with micro-structures.

  8. Noncontact conductivity and dielectric measurement for high throughput roll-to-roll nanomanufacturing.

    PubMed

    Orloff, Nathan D; Long, Christian J; Obrzut, Jan; Maillaud, Laurent; Mirri, Francesca; Kole, Thomas P; McMichael, Robert D; Pasquali, Matteo; Stranick, Stephan J; Liddle, J Alexander

    2015-01-01

    Advances in roll-to-roll processing of graphene and carbon nanotubes have at last led to the continuous production of high-quality coatings and filaments, ushering in a wave of applications for flexible and wearable electronics, woven fabrics, and wires. These applications often require specific electrical properties, and hence precise control over material micro- and nanostructure. While such control can be achieved, in principle, by closed-loop processing methods, there are relatively few noncontact and nondestructive options for quantifying the electrical properties of materials on a moving web at the speed required in modern nanomanufacturing. Here, we demonstrate a noncontact microwave method for measuring the dielectric constant and conductivity (or geometry for samples of known dielectric properties) of materials in a millisecond. Such measurement times are compatible with current and future industrial needs, enabling real-time materials characterization and in-line control of processing variables without disrupting production. PMID:26592441

  9. Noncontact conductivity and dielectric measurement for high throughput roll-to-roll nanomanufacturing

    NASA Astrophysics Data System (ADS)

    Orloff, Nathan D.; Long, Christian J.; Obrzut, Jan; Maillaud, Laurent; Mirri, Francesca; Kole, Thomas P.; McMichael, Robert D.; Pasquali, Matteo; Stranick, Stephan J.; Alexander Liddle, J.

    2015-11-01

    Advances in roll-to-roll processing of graphene and carbon nanotubes have at last led to the continuous production of high-quality coatings and filaments, ushering in a wave of applications for flexible and wearable electronics, woven fabrics, and wires. These applications often require specific electrical properties, and hence precise control over material micro- and nanostructure. While such control can be achieved, in principle, by closed-loop processing methods, there are relatively few noncontact and nondestructive options for quantifying the electrical properties of materials on a moving web at the speed required in modern nanomanufacturing. Here, we demonstrate a noncontact microwave method for measuring the dielectric constant and conductivity (or geometry for samples of known dielectric properties) of materials in a millisecond. Such measurement times are compatible with current and future industrial needs, enabling real-time materials characterization and in-line control of processing variables without disrupting production.

  10. Noncontact conductivity and dielectric measurement for high throughput roll-to-roll nanomanufacturing

    PubMed Central

    Orloff, Nathan D.; Long, Christian J.; Obrzut, Jan; Maillaud, Laurent; Mirri, Francesca; Kole, Thomas P.; McMichael, Robert D.; Pasquali, Matteo; Stranick, Stephan J.; Alexander Liddle, J.

    2015-01-01

    Advances in roll-to-roll processing of graphene and carbon nanotubes have at last led to the continuous production of high-quality coatings and filaments, ushering in a wave of applications for flexible and wearable electronics, woven fabrics, and wires. These applications often require specific electrical properties, and hence precise control over material micro- and nanostructure. While such control can be achieved, in principle, by closed-loop processing methods, there are relatively few noncontact and nondestructive options for quantifying the electrical properties of materials on a moving web at the speed required in modern nanomanufacturing. Here, we demonstrate a noncontact microwave method for measuring the dielectric constant and conductivity (or geometry for samples of known dielectric properties) of materials in a millisecond. Such measurement times are compatible with current and future industrial needs, enabling real-time materials characterization and in-line control of processing variables without disrupting production. PMID:26592441

  11. Eco green flexible hybrid photovoltaic-thermoelectric solar cells with nanoimprint technology and roll-to-roll manufacturing

    NASA Astrophysics Data System (ADS)

    Varadan, Vijay K.; Choi, Sang H.

    2010-04-01

    This paper explores the technical and commercial feasibility of nanotechnology based, high-efficiency, photovoltaic-thermoelectric hybrid solar cells as an environmentally-friendly, renewable energy source for residential and commercial buildings. To convert as much as possible of the usable photovoltaic (58% of the Energy Density) and thermoelectric (42% of the Energy Density) solar spectrum into electricity, a hybrid multilayer system is presented which comprises of 1) carbon nanotube (CNT) embedded in conducting polymers such as P3HT (poly(3-hexylthiophene) or P3OT (poly3-octylthiophene), 2) 3D gold nanostructures exhibiting plasmonic resonances for energy conversion, 3) nanoantenna architecture to capture IR energy, 4) a composite of Bi2Te3, SiGe nanocrystals and Au nanoshells as thermoelectric energy conversion layer, 5) configuration of the above items engineered in the form of meta-material designs that by virtue of their 3D structures ensure that incident light is neither reflected nor transmitted, but is rather all absorbed, 6) a multilayer arrangement of the above layers in a fractal architecture to capture all the wavelengths from 200 to 3000 nm8 and the matching electronic interface for each layer. The roll-to-roll manufacturing method presented will enable economical large-scale production of solar panels. This potentially transformational technology has the ability to replace the Si solar cell technology by reducing costs from 0.18/KWh to 0.003/KWh while introducing a more environmentally-friendly manufacturing process.

  12. Integrated optical interconnection for polymeric planar lightwave circuit device using roll-to-roll ultraviolet imprint

    NASA Astrophysics Data System (ADS)

    Cho, Sang Uk; Kang, Ho Ju; Chang, Sunghwan; Choi, Doo-sun; Kim, Chang-Seok; Jeong, Myung Yung

    2014-08-01

    We propose an integrated structure that combines chip and fiber array blocks for optical interconnection with a polymeric planar lightwave circuit (PLC) device using the roll-to-roll imprint process. The fiber array blocks and PLC chip of the integrated structure are fabricated on the same substrate, and the alignments in the three spatial directions were established with the insertion of an optical fiber. The characteristics of the integrated structure were evaluated by fabricating a 1×2 optical splitter device. The structure had an insertion loss of 3.9 dB, and the optical uniformity of the channel was 0.1 dB, indicating that the same performance for an active alignment can be expected.

  13. Roll-to-roll printed resistive WORM memory on a flexible substrate.

    PubMed

    Leppäniemi, Jaakko; Mattila, Tomi; Kololuoma, Terho; Suhonen, Mika; Alastalo, Ari

    2012-08-01

    The fabrication process and the operation characteristics of a fully roll-to-roll printed resistive write-once-read-many memory on a flexible substrate are presented. The low-voltage (<10 V) write operation of the memories from a high resistivity '0' state to a low resistivity '1' state is based on the rapid electrical sintering of bits containing silver nanoparticles. The bit ink is formulated by mixing two commercially available silver nanoparticle inks in order to tune the initial square resistance of the bits and to create a self-organized network of percolating paths. The electrical performance of the memories, including read and write characteristics, is described and the long-term stability of the less stable '0' state is studied in different environmental conditions. The memories can find use in low-cost mass printing applications. PMID:22782128

  14. Mechanism of forming defects in roll-to-roll hot embossing of micro-pyramid arrays: II. Numerical study

    NASA Astrophysics Data System (ADS)

    Wang, Jin; Yi, Peiyun; Deng, Yujun; Peng, Linfa; Lai, Xinmin; Ni, Jun

    2015-11-01

    Roll-to-roll (R2R) hot embossing is a continuous imprinting technique for the replication of large-area microstructures. Polymer deformation and recovery behavior is more complicated in this process than in the traditional plate-to-plate mode, especially for the embossing of 3-dimensional (3D) structures, such as the micro-pyramid structure used for reflective film. As a result, forming defects of poor shape and dimensional accuracy are more likely to emerge and are of greater diversity, which may negatively influence product quality and must be eliminated. In our previous experimental study, we have defined several types of forming defects that are commonly seen in embossed micro-pyramid arrays and have discussed the influence of processing parameters on the forming defects systematically. What is presented in this article is devoted to the simulation analysis of the forming mechanism of three typical types of forming defect: the platform-like defect, the bubble-like defect and the collapse-like defect. A 3D finite element model is established for the simulation analysis, in which the polymer resist is treated as a viscoelastic material based on the general Maxwell model. The simulation results clearly reveal the correlation between the forming defects and the processing conditions, indicating that the platform-like defect and the bubble-like defect are caused by material transport problems while the collapse-like defect results from polymer recovery. The underlying mechanisms for the forming defects disclosed in this research can provide effective guidelines for better process control as well as for improved design of the R2R hot embossing system.

  15. Compact Roll-to-Roll Coater for in Situ X-ray Diffraction Characterization of Organic Electronics Printing.

    PubMed

    Gu, Xiaodan; Reinspach, Julia; Worfolk, Brian J; Diao, Ying; Zhou, Yan; Yan, Hongping; Gu, Kevin; Mannsfeld, Stefan; Toney, Michael F; Bao, Zhenan

    2016-01-27

    We describe a compact roll-to-roll (R2R) coater that is capable of tracking the crystallization process of semiconducting polymers during solution printing using X-ray scattering at synchrotron beamlines. An improved understanding of the morphology evolution during the solution-processing of organic semiconductor materials during R2R coating processes is necessary to bridge the gap between "lab" and "fab". The instrument consists of a vacuum chuck to hold the flexible plastic substrate uniformly flat for grazing incidence X-ray scattering. The time resolution of the drying process that is achievable can be tuned by controlling two independent motor speeds, namely, the speed of the moving flexible substrate and the speed of the printer head moving in the opposite direction. With this novel design, we are able to achieve a wide range of drying time resolutions, from tens of milliseconds to seconds. This allows examination of the crystallization process over either fast or slow drying processes depending on coating conditions. Using regioregular poly(3-hexylthiophene-2,5-diyl) (P3HT) and phenyl-C61-butyric acid methyl ester (PCBM) inks based on two different solvents as a model system, we demonstrate the capability of our in situ R2R printing tool by observing two distinct crystallization processes for inks drying from the solvents with different boiling points (evaporation rates). We also observed delayed on-set point for the crystallization of P3HT polymer in the 1:1 P3HT/PCBM BHJ blend, and the inhibited crystallization of the P3HT during the late stage of the drying process. PMID:26714412

  16. Large format cylindrical lens films formed by roll-to-roll ultraviolet embossing and applications as diffusion films

    NASA Astrophysics Data System (ADS)

    Shan, X. C.; Liu, T.; Mohaime, M.; Salam, B.; Liu, Y. C.

    2015-03-01

    A roll-to-roll (R2R) ultraviolet (UV) embossing system has been developed for manufacturing micro features on continuous flexible films. The R2R UV embossing system, which has an embossing roller of 160 mm in diameter, can handle flexible polymer films with a width up to 500 mm and thickness ranging from 0.05 to 0.5 mm. A metal sheet template with micro features on its surface is mounted to the embossing roller and used as embossing mould. A slot die coating unit that has a coating width of 250 mm is used to deposit liquid UV curable resin on polymer films and coating thickness ranging from 10 to 50 µm has been achieved. Continuous roll-to-roll UV embossing is conducted and optical films with cylindrical lens arrays (curvature radius = 112  ±  2 µm, sag height = 28  ±  0.5 µm and pitch = 150  ±  2 µm) are formed. The optical films are used for diffusion to improve light uniformity of a printed lighting film that consists of lighting stripes and dark blank lines. The evaluation results show that the non-uniformity of light intensity can be reduced from 30% (with only lighting panel) to about 3% with the cylindrical lens films.

  17. Patterned Immobilization of Antibodies within Roll-to-Roll Hot Embossed Polymeric Microfluidic Channels

    PubMed Central

    Feyssa, Belachew; Liedert, Christina; Kivimaki, Liisa; Johansson, Leena-Sisko; Jantunen, Heli; Hakalahti, Leena

    2013-01-01

    This paper describes a method for the patterned immobilization of capture antibodies into a microfluidic platform fabricated by roll-to-roll (R2R) hot embossing on poly (methyl methacrylate) (PMMA). Covalent attachment of antibodies was achieved by two sequential inkjet printing steps. First, a polyethyleneimine (PEI) layer was deposited onto oxygen plasma activated PMMA foil and further cross-linked with glutaraldehyde (GA) to provide an amine-reactive aldehyde surface (PEI-GA). This step was followed by a second deposition of antibody by overprinting on the PEI-GA patterned PMMA foil. The PEI polymer ink was first formulated to ensure stable drop formation in inkjet printing and the printed films were characterized using atomic force microscopy (AFM) and X-ray photoelectron spectroscopy (XPS). Anti-CRP antibody was patterned on PMMA foil by the developed method and bonded permanently with R2R hot embossed PMMA microchannels by solvent bonding lamination. The functionality of the immobilized antibody inside the microfluidic channel was evaluated by fluorescence-based sandwich immunoassay for detection of C-reactive protein (CRP). The antibody-antigen assay exhibited a good level of linearity over the range of 10 ng/ml to 500 ng/ml (R2 = 0.991) with a calculated detection limit of 5.2 ng/ml. The developed patterning method is straightforward, rapid and provides a versatile approach for creating multiple protein patterns in a single microfluidic channel for multiplexed immunoassays. PMID:23874811

  18. Towards high-rate fabrication of photonic devices utilizing a combination of roll-to-roll compatible imprint lithography and ink jet printing methods

    NASA Astrophysics Data System (ADS)

    Lin, Xiaohui; Ling, Tao; Subbaraman, Harish; Guo, L. Jay; Chen, Ray T.

    2013-03-01

    Traditionally, polymer photonic devices are fabricated using clean-room processes such as photolithography, electron beam lithography, reactive ion etching (RIE) and lift-off methods etc, which leads to long fabrication time, low throughput and high cost. We describe in this paper a novel process for fabricating polymer photonic devices using a combination of imprinting and ink jet printing methods, which provides high throughput on a variety of rigid and flexible substrates with low cost. Particularly, we demonstrate a thermo-optic switch and an electro-optic modulator. In the rib waveguide patterning, the imprint lithography transfers the waveguide pattern from a soft mold to UV-15LV bottom cladding layer. The soft mold is replicated from a silicon master mold and rendered hydrophobic to ensure successful de-molding. Ink jet printing method is used to deposit the core layer in thermo-optic switch and electrode layers in electro-optic modulator. Compared to spin-coating method, the use of print-on-demand method greatly reduces material consumption and process complexity. Every step involved has the potential to be fully compatible with roll-toroll (R2R) volume production. For example, the soft mold can be wrapped around a cylinder to realized roll-to-roll imprinting. By combining R2R imprint lithography with ink jet printing, fabrication of large volume and large area multi-layer polymer photonic devices can be realized.

  19. Roll-to-roll embedded conductive structures integrated into organic photovoltaic devices

    NASA Astrophysics Data System (ADS)

    van de Wiel, H. J.; Galagan, Y.; van Lammeren, T. J.; de Riet, J. F. J.; Gilot, J.; Nagelkerke, M. G. M.; Lelieveld, R. H. C. A. T.; Shanmugam, S.; Pagudala, A.; Hui, D.; Groen, W. A.

    2013-12-01

    Highly conductive screen printed metallic (silver) structures (current collecting grids) combined with poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) are a viable replacement for indium tin oxide (ITO) and inkjet printed silver as transparent electrode materials. To provide successful integration into organic photovoltaic (OPV) devices, screen printed silver current collecting grids should be embedded into a substrate to avoid topology issues. In this study micron-thick conductive structures are embedded and integrated into OPV devices. The embedded structures are produced roll-to-roll with optimized process settings and materials. Topology measurements show that the embedded grids are well suited for integration into OPV devices since the surface is almost without spikes and has low surface roughness. JV measurements of OPV devices with embedded structures on a polyethylene terephthalate/silicon nitride (PET/SiN) substrate show an efficiency of 2.15%, which is significantly higher than identical flexible devices with ITO (1.02%) and inkjet printed silver (1.48%). The use of embedded screen printed silver instead of ITO and inkjet printed silver in OPV devices will allow for higher efficiency devices which can be produced with larger design and process freedom.

  20. Roll-to-Roll Screen Printed Radio Frequency Identification Transponder Antennas for Vehicle Tracking Systems

    NASA Astrophysics Data System (ADS)

    Zichner, Ralf; Baumann, Reinhard R.

    2013-05-01

    Vehicle tracking systems based on ultra high frequency (UHF) radio frequency identification (RFID) technology are already introduced to control the access to car parks and corporate premises. For this field of application so-called Windshield RFID transponder labels are used, which are applied to the inside of the windshield. State of the art for manufacturing these transponder antennas is the traditional lithography/etching approach. Furthermore the performance of these transponders is limited to a reading distance of approximately 5 m which results in car speed limit of 5 km/h for identification. However, to achieve improved performance compared to existing all-purpose transponders and a dramatic cost reduction, an optimized antenna design is needed which takes into account the special dielectric and in particular metallic car environment of the tag and an roll-to-roll (R2R) printing manufacturing process. In this paper we focus on the development of a customized UHF RFID transponder antenna design, which is adopted for vehicle geometry as well as R2R screen printing manufacturing processes.

  1. In-line roll-to-roll metrology for flexible electronics

    NASA Astrophysics Data System (ADS)

    Kimbrough, Brad

    2015-09-01

    The flexible electronics market continues to grow at a rapid pace. Increasing numbers of applications employ the flexible components including displays, biomedical devices, smart apparel, and advanced sensors. To maintain performance and lifetime, many characteristics of the substrate and deposited layers must be monitored. This includes defects, surface roughness, and feature alignment. Ideally, in-situ metrology can be employed in roll-to-roll (R2R) equipment to allow for real-time process control. This presents the necessary three-dimensional metrology system with several challenging requirements: high vertical and transverse resolution, large field-of-view, extremely fast measurement times, and robust vibration immunity. This paper will discuss the design and performance of a compact, low-cost, large-field interferometric probe for in-situ measurement of R2R substrates. Samples with a variety of known and unknown features and roughnesses will be measured to characterize the performance of the system. Static and moving substrates will be measured to examine effects on results. Optimization of processing to allow for on-board analysis will be examined. Lastly, the paper will discuss how such probes may be arrayed to provide a high degree of areal coverage of the flexible substrate under test.

  2. Large Scale Triboelectric Nanogenerator and Self-Powered Pressure Sensor Array Using Low Cost Roll-to-Roll UV Embossing

    NASA Astrophysics Data System (ADS)

    Dhakar, Lokesh; Gudla, Sudeep; Shan, Xuechuan; Wang, Zhiping; Tay, Francis Eng Hock; Heng, Chun-Huat; Lee, Chengkuo

    2016-02-01

    Triboelectric nanogenerators (TENGs) have emerged as a potential solution for mechanical energy harvesting over conventional mechanisms such as piezoelectric and electromagnetic, due to easy fabrication, high efficiency and wider choice of materials. Traditional fabrication techniques used to realize TENGs involve plasma etching, soft lithography and nanoparticle deposition for higher performance. But lack of truly scalable fabrication processes still remains a critical challenge and bottleneck in the path of bringing TENGs to commercial production. In this paper, we demonstrate fabrication of large scale triboelectric nanogenerator (LS-TENG) using roll-to-roll ultraviolet embossing to pattern polyethylene terephthalate sheets. These LS-TENGs can be used to harvest energy from human motion and vehicle motion from embedded devices in floors and roads, respectively. LS-TENG generated a power density of 62.5 mW m-2. Using roll-to-roll processing technique, we also demonstrate a large scale triboelectric pressure sensor array with pressure detection sensitivity of 1.33 V kPa-1. The large scale pressure sensor array has applications in self-powered motion tracking, posture monitoring and electronic skin applications. This work demonstrates scalable fabrication of TENGs and self-powered pressure sensor arrays, which will lead to extremely low cost and bring them closer to commercial production.

  3. Large Scale Triboelectric Nanogenerator and Self-Powered Pressure Sensor Array Using Low Cost Roll-to-Roll UV Embossing.

    PubMed

    Dhakar, Lokesh; Gudla, Sudeep; Shan, Xuechuan; Wang, Zhiping; Tay, Francis Eng Hock; Heng, Chun-Huat; Lee, Chengkuo

    2016-01-01

    Triboelectric nanogenerators (TENGs) have emerged as a potential solution for mechanical energy harvesting over conventional mechanisms such as piezoelectric and electromagnetic, due to easy fabrication, high efficiency and wider choice of materials. Traditional fabrication techniques used to realize TENGs involve plasma etching, soft lithography and nanoparticle deposition for higher performance. But lack of truly scalable fabrication processes still remains a critical challenge and bottleneck in the path of bringing TENGs to commercial production. In this paper, we demonstrate fabrication of large scale triboelectric nanogenerator (LS-TENG) using roll-to-roll ultraviolet embossing to pattern polyethylene terephthalate sheets. These LS-TENGs can be used to harvest energy from human motion and vehicle motion from embedded devices in floors and roads, respectively. LS-TENG generated a power density of 62.5 mW m(-2). Using roll-to-roll processing technique, we also demonstrate a large scale triboelectric pressure sensor array with pressure detection sensitivity of 1.33 V kPa(-1). The large scale pressure sensor array has applications in self-powered motion tracking, posture monitoring and electronic skin applications. This work demonstrates scalable fabrication of TENGs and self-powered pressure sensor arrays, which will lead to extremely low cost and bring them closer to commercial production. PMID:26905285

  4. Large Scale Triboelectric Nanogenerator and Self-Powered Pressure Sensor Array Using Low Cost Roll-to-Roll UV Embossing

    PubMed Central

    Dhakar, Lokesh; Gudla, Sudeep; Shan, Xuechuan; Wang, Zhiping; Tay, Francis Eng Hock; Heng, Chun-Huat; Lee, Chengkuo

    2016-01-01

    Triboelectric nanogenerators (TENGs) have emerged as a potential solution for mechanical energy harvesting over conventional mechanisms such as piezoelectric and electromagnetic, due to easy fabrication, high efficiency and wider choice of materials. Traditional fabrication techniques used to realize TENGs involve plasma etching, soft lithography and nanoparticle deposition for higher performance. But lack of truly scalable fabrication processes still remains a critical challenge and bottleneck in the path of bringing TENGs to commercial production. In this paper, we demonstrate fabrication of large scale triboelectric nanogenerator (LS-TENG) using roll-to-roll ultraviolet embossing to pattern polyethylene terephthalate sheets. These LS-TENGs can be used to harvest energy from human motion and vehicle motion from embedded devices in floors and roads, respectively. LS-TENG generated a power density of 62.5 mW m−2. Using roll-to-roll processing technique, we also demonstrate a large scale triboelectric pressure sensor array with pressure detection sensitivity of 1.33 V kPa−1. The large scale pressure sensor array has applications in self-powered motion tracking, posture monitoring and electronic skin applications. This work demonstrates scalable fabrication of TENGs and self-powered pressure sensor arrays, which will lead to extremely low cost and bring them closer to commercial production. PMID:26905285

  5. Metrology and instrumentation challenges with high-rate, roll-to-roll manufacturing of flexible electronic systems

    NASA Astrophysics Data System (ADS)

    Subbaraman, Harish; Lin, Xiaohui; Xu, Xiaochuan; Dodabalapur, Ananth; Guo, L. Jay; Chen, Ray T.

    2012-10-01

    In this paper, we discuss the metrology and instrumentation challenges that need to be overcome in order to realize true implementation of roll-to-roll manufacturing of flexible electronic systems. Several metrology and instrumentation challenges involved such as availability of particulate-free high quality substrate, development and implementation of high-speed in-line and off-line inspection and diagnostic tools with adaptive control for patterned and unpatterned material films, development of reliable hardware, etc need to be addressed and overcome in order to realize a successful manufacturing process. Due to extreme resolution requirements compared to print media, the burden of software and hardware tools on the throughput also needs to be carefully determined. Moreover, the effect of web wander and variations in web speed need to accurately be determined in the design of the system hardware and software. Realization of successful metrology and instrumentation by overcoming the challenges for the development of a roll-to-roll manufacturing system for flexible electronic systems opens limitless possibilities for the deployment of high performance flexible electronic components in a variety of applications including communication, sensing, medicine, agriculture, energy, lighting etc.

  6. Roll-to-roll nanopatterning using jet and flash imprint lithography

    NASA Astrophysics Data System (ADS)

    Ahn, Sean; Ganapathisubramanian, Maha; Miller, Mike; Yang, Jack; Choi, Jin; Xu, Frank; Resnick, Douglas J.; Sreenivasan, S. V.

    2012-03-01

    The ability to pattern materials at the nanoscale can enable a variety of applications ranging from high density data storage, displays, photonic devices and CMOS integrated circuits to emerging applications in the biomedical and energy sectors. These applications require varying levels of pattern control, short and long range order, and have varying cost tolerances. Extremely large area R2R manufacturing on flexible substrates is ubiquitous for applications such as paper and plastic processing. It combines the benefits of high speed and inexpensive substrates to deliver a commodity product at low cost. The challenge is to extend this approach to the realm of nanopatterning and realize similar benefits. The cost of manufacturing is typically driven by speed (or throughput), tool complexity, cost of consumables (materials used, mold or master cost, etc.), substrate cost, and the downstream processing required (annealing, deposition, etching, etc.). In order to achieve low cost nanopatterning, it is imperative to move towards high speed imprinting, less complex tools, near zero waste of consumables and low cost substrates. The Jet and Flash Imprint Lithography (J-FILTM) process uses drop dispensing of UV curable resists to assist high resolution patterning for subsequent dry etch pattern transfer. The technology is actively being used to develop solutions for memory markets including Flash memory and patterned media for hard disk drives. In this paper we address the key challenges for roll based nanopatterning by introducing a novel concept: Ink Jet based Roll-to-Roll Nanopatterning. To address this challenge, we have introduced a J-FIL based demonstrator product, the LithoFlex 100. Topics that are discussed in the paper include tool design and process performance. In addition, we have used the LithoFlex 100 to fabricate high performance wire grid polarizers on flexible polycarbonate (PC) films. Transmission of better than 80% and extinction ratios on the order of

  7. The effect of mold materials on the overlay accuracy of a roll-to-roll imprinting system using UV LED illumination within a transparent mold

    NASA Astrophysics Data System (ADS)

    Choi, Sungwoo; Kook, YunHo; Kim, ChulHo; Yoo, SoonSung; Park, Kwon-Shik; Kim, Seok-min; Kang, Shinill

    2016-06-01

    Although several studies on the roll-to-roll (R2R) imprinting process have reported achieving flexible electronics, improving the alignment accuracy in the overlay process of R2R imprinting is recognized as the biggest problem for the commercialization of this technology. For an overlay technique with high alignment accuracy, it is essential to develop a roll mold with high positional accuracy. In this study, a method for fabricating a roll mold with high positional accuracy is proposed by wrapping a thin glass substrate flexible mold around the transparent roll base, because it can provide higher mechanical strength and thermal stability than a conventional polymer substrate. To confirm the usability of the proposed process, the prepared roll mold was used to fabricate a test pattern of thin-film transistor backplane for a rollable display. The positional and overlay accuracy of the roll mold with the proposed thin glass substrate flexible mold were compared with the roll mold with a conventional polymer substrate flexible mold. Large-area transparent flexible molds with a size of 470  ×  370 mm were fabricated by an ultraviolet (UV) imprinting process on thin glass and polyethylene terephthalate substrates, and these flexible molds were wrapped around a roll base of 125 mm radius through a precision alignment process. After an anti-adhesion treatment and the wrapping process, the roll mold with the polymer substrate showed a ~180 μm positional error, whereas the thin glass substrate showed a ~30 μm positional error. After the overlay process using the R2R imprinting system with the alignment system, an average overlay error of ~3 μm was obtained when the thin glass flexible wrapped roll mold was used, whereas a ~22 μm overlay error was obtained when the polymer substrate flexible wrapped roll mold was used.

  8. Large Area 2D and 3D Colloidal Photonic Crystals Fabricated by a Roll-to-Roll Langmuir-Blodgett Method.

    PubMed

    Parchine, Mikhail; McGrath, Joe; Bardosova, Maria; Pemble, Martyn E

    2016-06-14

    We present our results on the fabrication of large area colloidal photonic crystals on flexible poly(ethylene terephthalate) (PET) film using a roll-to-roll Langmuir-Blodgett technique. Two-dimensional (2D) and three-dimensional (3D) colloidal photonic crystals from silica nanospheres (250 and 550 nm diameter) with a total area of up to 340 cm(2) have been fabricated in a continuous manner compatible with high volume manufacturing. In addition, the antireflective properties and structural integrity of the films have been enhanced via the use of a second roll-to-roll process, employing a slot-die coating of an optical adhesive over the photonic crystal films. Scanning electron microscopy images, atomic force microscopy images, and UV-vis optical transmission and reflection spectra of the fabricated photonic crystals are analyzed. This analysis confirms the high quality of the 2D and 3D photonic crystals fabricated by the roll-to-roll LB technique. Potential device applications of the large area 2D and 3D colloidal photonic crystals on flexible PET film are briefly reviewed. PMID:27218474

  9. Metal-assisted exfoliation (MAE): green, roll-to-roll compatible method for transferring graphene to flexible substrates

    NASA Astrophysics Data System (ADS)

    Zaretski, Aliaksandr V.; Moetazedi, Herad; Kong, Casey; Sawyer, Eric J.; Savagatrup, Suchol; Valle, Eduardo; O'Connor, Timothy F.; Printz, Adam D.; Lipomi, Darren J.

    2015-01-01

    Graphene is expected to play a significant role in future technologies that span a range from consumer electronics, to devices for the conversion and storage of energy, to conformable biomedical devices for healthcare. To realize these applications, however, a low-cost method of synthesizing large areas of high-quality graphene is required. Currently, the only method to generate large-area single-layer graphene that is compatible with roll-to-roll manufacturing destroys approximately 300 kg of copper foil (thickness = 25 μm) for every 1 g of graphene produced. This paper describes a new environmentally benign and scalable process of transferring graphene to flexible substrates. The process is based on the preferential adhesion of certain thin metallic films to graphene; separation of the graphene from the catalytic copper foil is followed by lamination to a flexible target substrate in a process that is compatible with roll-to-roll manufacturing. The copper substrate is indefinitely reusable and the method is substantially greener than the current process that uses relatively large amounts of corrosive etchants to remove the copper. The sheet resistance of the graphene produced by this new process is unoptimized but should be comparable in principle to that produced by the standard method, given the defects observable by Raman spectroscopy and the presence of process-induced cracks. With further improvements, this green, inexpensive synthesis of single-layer graphene could enable applications in flexible, stretchable, and disposable electronics, low-profile and lightweight barrier materials, and in large-area displays and photovoltaic modules.

  10. Roll-to-roll printed silver nanowires for increased stability of flexible ITO-free organic solar cell modules

    NASA Astrophysics Data System (ADS)

    Dos Reis Benatto, Gisele A.; Roth, Bérenger; Corazza, Michael; Søndergaard, Roar R.; Gevorgyan, Suren A.; Jørgensen, Mikkel; Krebs, Frederik C.

    2015-12-01

    We report the use of roll-to-roll printed silver nanowire networks as front electrodes for fully roll-to-roll processed flexible indium-tin-oxide (ITO) free OPV modules. We prepared devices with two types of back electrodes, a simple PEDOT:PSS back electrode and a PEDOT:PSS back electrode with a printed silver grid in order to simultaneously explore the influence of the back electrode structure on the operational stability of the modules that did not include any UV-protection. We subjected the devices to stability testing under a number of protocols recommended by the international summit on OPV stability (ISOS). We explored accelerated ISOS-D-2, ISOS-D-3, ISOS-L-2, ISOS-L-3, ISOS-O-1 and ISOS-O-2 testing protocols and compared the performance to previous reports employing the same testing protocols on devices with PEDOT:PSS instead of the silver nanowires in the front electrode. We find significantly increased operational stability across all ISOS testing protocols over the course of the study and conclude that replacement of PEDOT:PSS in the front electrode with silver nanowires increase operational stability by up to 1000%. The duration of the tests were in the range of 140-360 days. The comparison of front and back electrode stability in this study shows that the modules with silver nanowire front electrodes together with a composite back electrode comprising PEDOT:PSS and a silver grid present the best operational stability.

  11. Roll-to-roll gravure with nanomaterials for printing smart packaging.

    PubMed

    Jung, Minhun; Kim, Junseok; Koo, Hyunmo; Lee, Wookyu; Subramanian, Vivek; Cho, Gyoujin

    2014-02-01

    Roll-to-roll (R2R) gravure is considered one of the highest throughput tools for manufacturing inexpensive and flexible ubiquitous IT devices called "smart packaging" in which NFC (near-field communication) transponder, sensors, ADC (analog-to-digital converter), simple processor and signage are all integrated on paper or plastic foils. In this review, we show R2R gravure can be employed to print smart packaging, starting from printing simple electrodes, dielectrics, capacitors, diodes and thin film transistors with appropriate nanomaterial-based inks on plastic foils. PMID:24749427

  12. A roll-to-roll sub-wavelength grating applied for a liquid crystal backlight

    NASA Astrophysics Data System (ADS)

    Lee, Chi-Hung; Liu, C. W.; Lin, S. C.

    A roll-to-roll imprinted optical setup consisting of a gratings upon a light bar (LB) is designed to shrink the coupling length between a point light source and a light guide for application in a mobile phone display. Grating period and shape was analyzed by investigating the relationship between the angular distributions of incident beam on the grating and the illumination characteristics of LED. The design has a potential to eliminate the brightness enhancement film (BEF) for a red-green-blue (RGB) light-emitting diode (LED) or a cold cathode fluorescent lamp (CCFL) backlight module in the LCD systems.

  13. Effects of preheating and cooling durations on roll-to-roll hot embossing.

    PubMed

    Kim, Seyoung; Son, Youngsu; Park, Heechang; Kim, Byungin; Yun, Dongwon

    2015-02-01

    In this study, we examined the sensitivity of embossed pattern depth to preheat supply and cooling and investigated how the pattern type and density affect the embossed depth. The main factors that affect embossed pattern qualities of roll-to-roll hot embossing, such as roller temperature, roller speed, and applied force, were determined using the response surface methodology. Eight conditions were then added to determine the time-dependent effects of heat transfer with custom-designed preheating and cooling systems. An extended preheat time for the polymethylmethacrylate substrate contributed to the significant change in the embossed depth, whereas the substrate-cooling did not exhibit a clear increasing or decreasing trend. Larger embossed depths were achieved in the horizontal patterns with lower density than in the vertical patterns, and the lower pattern densities showed greater embossed depths in most embossing conditions. We expect that this result will help to understand the effects of the pre- and posttreatment of roll-to-roll hot embossing by employing time duration factors of heat transfer, depending on the mold pattern type and density. PMID:25311866

  14. Design and implementation of adaptive PI control schemes for web tension control in roll-to-roll (R2R) manufacturing.

    PubMed

    Raul, Pramod R; Pagilla, Prabhakar R

    2015-05-01

    In this paper, two adaptive Proportional-Integral (PI) control schemes are designed and discussed for control of web tension in Roll-to-Roll (R2R) manufacturing systems. R2R systems are used to transport continuous materials (called webs) on rollers from the unwind roll to the rewind roll. Maintaining web tension at the desired value is critical to many R2R processes such as printing, coating, lamination, etc. Existing fixed gain PI tension control schemes currently used in industrial practice require extensive tuning and do not provide the desired performance for changing operating conditions and material properties. The first adaptive PI scheme utilizes the model reference approach where the controller gains are estimated based on matching of the actual closed-loop tension control systems with an appropriately chosen reference model. The second adaptive PI scheme utilizes the indirect adaptive control approach together with relay feedback technique to automatically initialize the adaptive PI gains. These adaptive tension control schemes can be implemented on any R2R manufacturing system. The key features of the two adaptive schemes is that their designs are simple for practicing engineers, easy to implement in real-time, and automate the tuning process. Extensive experiments are conducted on a large experimental R2R machine which mimics many features of an industrial R2R machine. These experiments include trials with two different polymer webs and a variety of operating conditions. Implementation guidelines are provided for both adaptive schemes. Experimental results comparing the two adaptive schemes and a fixed gain PI tension control scheme used in industrial practice are provided and discussed. PMID:25555757

  15. Continuous roll-to-roll a-Si photovoltaic manufacturing technology. Annual subcontractor report, 1 April 1992--31 March 1993

    SciTech Connect

    Izu, M.

    1993-12-01

    This report describes work done under a 3-year program to advance ECD`s roll-to-roll, triple-junction photovoltaic manufacturing technologies, to reduce the module production costs, to increase the stabilized module performance, and to expand commercial capacity utilizing ECD technology. The specific 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD`s earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1.00 per peak watt. Accomplishments during Phase 1 included: (1) ECD successfully incorporated a high-performance Ag/metal-oxide back-reflector system into its continuous roll-to-roll commercial production operation. (2) High-quality a-Si-Ge narrow-band-gap solar cells were incorporated into the manufacturing. (3) ECD demonstrated the continuous roll-to-roll production of high-efficiency, triple-junction, two-band-gap solar cells consistently and uniformly throughout a 762-m (2500-ft) run with high yield. (4) ECD achieved 11.1% initial sub-cell efficiency of triple-junction, two-band-gap a-Si alloy solar cells in the production line. (5) The world`s first 0.37-m{sup 2} (4-ft{sup 2}) PV modules were produced utilizing triple-junction spectrum-splitting solar cells manufactured in the production line. (6) As a result of process optimization to reduce the layer thickness and to improve the gas utilization, ECD achieved a 77% material cost reduction for germane and 58% reduction for disilane. Additionally, ECD developed a new low-cost module that saves approximately 30% in assembly material costs.

  16. Roll-to-roll-compatible, flexible, transparent electrodes based on self-nanoembedded Cu nanowires using intense pulsed light irradiation

    NASA Astrophysics Data System (ADS)

    Zhong, Zhaoyang; Woo, Kyoohee; Kim, Inhyuk; Hwang, Hyewon; Kwon, Sin; Choi, Young-Man; Lee, Youngu; Lee, Taik-Min; Kim, Kwangyoung; Moon, Jooho

    2016-04-01

    Copper nanowire (Cu NW)-based flexible transparent conductive electrodes (FTCEs) have been investigated in detail for use in various applications such as flexible touch screens, organic photovoltaics and organic light-emitting diodes. In this study, hexadecylamine (HDA) adsorbed onto the surface of NWs is changed into polyvinylpyrrolidone (PVP) via a ligand exchange process; the high-molecular-weight PVP enables high dispersion stability. Intense pulsed light (IPL) irradiation is used to remove organic species present on the surface of the NWs and to form direct connections between the NWs rapidly without any atmospheric control. NWs are self-nanoembedded into a plastic substrate after IPL irradiation, which results in a smooth surface, strong NW/substrate adhesion, excellent mechanical flexibility and enhanced oxidation stability. Moreover, Cu NW FTCEs with high uniformities are successfully fabricated on a large area (150 mm × 200 mm) via successive IPL irradiation that is synchronized with the motion of the sample stage. This study demonstrates the possibility of roll-to-roll-based, large-scale production of low-cost, high-performance Cu NW-based FTCEs.Copper nanowire (Cu NW)-based flexible transparent conductive electrodes (FTCEs) have been investigated in detail for use in various applications such as flexible touch screens, organic photovoltaics and organic light-emitting diodes. In this study, hexadecylamine (HDA) adsorbed onto the surface of NWs is changed into polyvinylpyrrolidone (PVP) via a ligand exchange process; the high-molecular-weight PVP enables high dispersion stability. Intense pulsed light (IPL) irradiation is used to remove organic species present on the surface of the NWs and to form direct connections between the NWs rapidly without any atmospheric control. NWs are self-nanoembedded into a plastic substrate after IPL irradiation, which results in a smooth surface, strong NW/substrate adhesion, excellent mechanical flexibility and enhanced

  17. Inkjetable and photo-curable resists for large-area and high-throughput roll-to-roll nanoimprint lithography

    NASA Astrophysics Data System (ADS)

    Thesen, Manuel W.; Nees, Dieter; Ruttloff, Stephan; Rumler, Maximilian; Rommel, Mathias; Schlachter, Florian; Grützner, Susanne; Vogler, Marko; Schleunitz, Arne; Grützner, Gabi

    2014-10-01

    We report on our development strategy of photo-curable resists for nanoimprint lithography (NIL) based on modularity. Starting with a basic formulation, we address two topics: the integration of fluorinated additives and the enhancement of the dry etching stability. We prove both concepts by the introduction of two different resists derived from the same basic formulation. The viscosity of the novel resist materials was optimized for inkjet dispensing at room temperature (RT). The novel resist materials can be applied either in NIL batch processes or in high-throughput roller processes. Batch-wise imprints were performed on various substrates such as Si or plastics, demonstrating the distinctive application versatility of the novel materials. Dry etching of spin-coated thin films on Si wafers was performed, demonstrating an etch stability versus Si of 3.5:1 by using the resist formulation with improved etching stability. Roll-to-roll NIL at high throughput on large areas was performed with web speeds of up to 30 m min-1 with different stamp materials. We conclude that all resists reported herein can be deposited via inkjet dispensing at RT, are suitable for continuous high-throughput imprinting on flexible substrates, and are applicable in step-wise NIL processes with good etch resistance in dry etch processes.

  18. Cotton-textile-enabled flexible self-sustaining power packs via roll-to-roll fabrication.

    PubMed

    Gao, Zan; Bumgardner, Clifton; Song, Ningning; Zhang, Yunya; Li, Jingjing; Li, Xiaodong

    2016-01-01

    With rising energy concerns, efficient energy conversion and storage devices are required to provide a sustainable, green energy supply. Solar cells hold promise as energy conversion devices due to their utilization of readily accessible solar energy; however, the output of solar cells can be non-continuous and unstable. Therefore, it is necessary to combine solar cells with compatible energy storage devices to realize a stable power supply. To this end, supercapacitors, highly efficient energy storage devices, can be integrated with solar cells to mitigate the power fluctuations. Here, we report on the development of a solar cell-supercapacitor hybrid device as a solution to this energy requirement. A high-performance, cotton-textile-enabled asymmetric supercapacitor is integrated with a flexible solar cell via a scalable roll-to-roll manufacturing approach to fabricate a self-sustaining power pack, demonstrating its potential to continuously power future electronic devices. PMID:27189776

  19. Cotton-textile-enabled flexible self-sustaining power packs via roll-to-roll fabrication

    PubMed Central

    Gao, Zan; Bumgardner, Clifton; Song, Ningning; Zhang, Yunya; Li, Jingjing; Li, Xiaodong

    2016-01-01

    With rising energy concerns, efficient energy conversion and storage devices are required to provide a sustainable, green energy supply. Solar cells hold promise as energy conversion devices due to their utilization of readily accessible solar energy; however, the output of solar cells can be non-continuous and unstable. Therefore, it is necessary to combine solar cells with compatible energy storage devices to realize a stable power supply. To this end, supercapacitors, highly efficient energy storage devices, can be integrated with solar cells to mitigate the power fluctuations. Here, we report on the development of a solar cell-supercapacitor hybrid device as a solution to this energy requirement. A high-performance, cotton-textile-enabled asymmetric supercapacitor is integrated with a flexible solar cell via a scalable roll-to-roll manufacturing approach to fabricate a self-sustaining power pack, demonstrating its potential to continuously power future electronic devices. PMID:27189776

  20. Cotton-textile-enabled flexible self-sustaining power packs via roll-to-roll fabrication

    NASA Astrophysics Data System (ADS)

    Gao, Zan; Bumgardner, Clifton; Song, Ningning; Zhang, Yunya; Li, Jingjing; Li, Xiaodong

    2016-05-01

    With rising energy concerns, efficient energy conversion and storage devices are required to provide a sustainable, green energy supply. Solar cells hold promise as energy conversion devices due to their utilization of readily accessible solar energy; however, the output of solar cells can be non-continuous and unstable. Therefore, it is necessary to combine solar cells with compatible energy storage devices to realize a stable power supply. To this end, supercapacitors, highly efficient energy storage devices, can be integrated with solar cells to mitigate the power fluctuations. Here, we report on the development of a solar cell-supercapacitor hybrid device as a solution to this energy requirement. A high-performance, cotton-textile-enabled asymmetric supercapacitor is integrated with a flexible solar cell via a scalable roll-to-roll manufacturing approach to fabricate a self-sustaining power pack, demonstrating its potential to continuously power future electronic devices.

  1. Transparent Conductive AGZO/Ag/AGZO Multilayers on PET Substrate by Roll-to-Roll Sputtering.

    PubMed

    Kim, Taehoon; Park, Kwangwon; Kim, Jongsu

    2016-02-01

    Indium-free Al and Ga-codoped ZnO (AGZO) multilayer films with nanoscale Ag interlayer were deposited by dual target roll-to-roll RF for AGZO and DC sputtering systems for Ag at room temperature for a large scale. The thicknesses of AGZO/Ag/AGZO multilayer were optimized by changing the roll speed: 0.15/1.1/0.15 m/min for AGZO/Ag/AGZO multilayers, respectively. The optimum thicknesses of AGZO/Ag/AGZO multilayer are 9.21, 8.32 and 8.04 nm, respectively. Optimized AGZO/Ag/AGZO multilayer films showed an excellent transparency (84% at 550 nm) and a low sheet resistance (9.2 omega/sq.) on PET substrates for opto-electronic applications. The effects of nanoscale Ag interlayer on optical and electrical properties of AGZO/Ag/AGZO multilayer films were discussed. PMID:27433648

  2. A fully roll-to-roll gravure-printed carbon nanotube-based active matrix for multi-touch sensors

    NASA Astrophysics Data System (ADS)

    Lee, Wookyu; Koo, Hyunmo; Sun, Junfeng; Noh, Jinsoo; Kwon, Kye-Si; Yeom, Chiseon; Choi, Younchang; Chen, Kevin; Javey, Ali; Cho, Gyoujin

    2015-12-01

    Roll-to-roll (R2R) printing has been pursued as a commercially viable high-throughput technology to manufacture flexible, disposable, and inexpensive printed electronic devices. However, in recent years, pessimism has prevailed because of the barriers faced when attempting to fabricate and integrate thin film transistors (TFTs) using an R2R printing method. In this paper, we report 20 × 20 active matrices (AMs) based on single-walled carbon nanotubes (SWCNTs) with a resolution of 9.3 points per inch (ppi) resolution, obtained using a fully R2R gravure printing process. By using SWCNTs as the semiconducting layer and poly(ethylene terephthalate) (PET) as the substrate, we have obtained a device yield above 98%, and extracted the key scalability factors required for a feasible R2R gravure manufacturing process. Multi-touch sensor arrays were achieved by laminating a pressure sensitive rubber onto the SWCNT-TFT AM. This R2R gravure printing system overcomes the barriers associated with the registration accuracy of printing each layer and the variation of the threshold voltage (Vth). By overcoming these barriers, the R2R gravure printing method can be viable as an advanced manufacturing technology, thus enabling the high-throughput production of flexible, disposable, and human-interactive cutting-edge electronic devices based on SWCNT-TFT AMs.

  3. A fully roll-to-roll gravure-printed carbon nanotube-based active matrix for multi-touch sensors.

    PubMed

    Lee, Wookyu; Koo, Hyunmo; Sun, Junfeng; Noh, Jinsoo; Kwon, Kye-Si; Yeom, Chiseon; Choi, Younchang; Chen, Kevin; Javey, Ali; Cho, Gyoujin

    2015-01-01

    Roll-to-roll (R2R) printing has been pursued as a commercially viable high-throughput technology to manufacture flexible, disposable, and inexpensive printed electronic devices. However, in recent years, pessimism has prevailed because of the barriers faced when attempting to fabricate and integrate thin film transistors (TFTs) using an R2R printing method. In this paper, we report 20 × 20 active matrices (AMs) based on single-walled carbon nanotubes (SWCNTs) with a resolution of 9.3 points per inch (ppi) resolution, obtained using a fully R2R gravure printing process. By using SWCNTs as the semiconducting layer and poly(ethylene terephthalate) (PET) as the substrate, we have obtained a device yield above 98%, and extracted the key scalability factors required for a feasible R2R gravure manufacturing process. Multi-touch sensor arrays were achieved by laminating a pressure sensitive rubber onto the SWCNT-TFT AM. This R2R gravure printing system overcomes the barriers associated with the registration accuracy of printing each layer and the variation of the threshold voltage (Vth). By overcoming these barriers, the R2R gravure printing method can be viable as an advanced manufacturing technology, thus enabling the high-throughput production of flexible, disposable, and human-interactive cutting-edge electronic devices based on SWCNT-TFT AMs. PMID:26635237

  4. A fully roll-to-roll gravure-printed carbon nanotube-based active matrix for multi-touch sensors

    PubMed Central

    Lee, Wookyu; Koo, Hyunmo; Sun, Junfeng; Noh, Jinsoo; Kwon, Kye-Si; Yeom, Chiseon; Choi, Younchang; Chen, Kevin; Javey, Ali; Cho, Gyoujin

    2015-01-01

    Roll-to-roll (R2R) printing has been pursued as a commercially viable high-throughput technology to manufacture flexible, disposable, and inexpensive printed electronic devices. However, in recent years, pessimism has prevailed because of the barriers faced when attempting to fabricate and integrate thin film transistors (TFTs) using an R2R printing method. In this paper, we report 20 × 20 active matrices (AMs) based on single-walled carbon nanotubes (SWCNTs) with a resolution of 9.3 points per inch (ppi) resolution, obtained using a fully R2R gravure printing process. By using SWCNTs as the semiconducting layer and poly(ethylene terephthalate) (PET) as the substrate, we have obtained a device yield above 98%, and extracted the key scalability factors required for a feasible R2R gravure manufacturing process. Multi-touch sensor arrays were achieved by laminating a pressure sensitive rubber onto the SWCNT-TFT AM. This R2R gravure printing system overcomes the barriers associated with the registration accuracy of printing each layer and the variation of the threshold voltage (Vth). By overcoming these barriers, the R2R gravure printing method can be viable as an advanced manufacturing technology, thus enabling the high-throughput production of flexible, disposable, and human-interactive cutting-edge electronic devices based on SWCNT-TFT AMs. PMID:26635237

  5. Fully Roll-to-Roll Gravure Printable Wireless (13.56 MHz) Sensor-Signage Tags for Smart Packaging

    NASA Astrophysics Data System (ADS)

    Kang, Hwiwon; Park, Hyejin; Park, Yongsu; Jung, Minhoon; Kim, Byung Chul; Wallace, Gordon; Cho, Gyoujin

    2014-06-01

    Integration of sensing capabilities with an interactive signage through wireless communication is enabling the development of smart packaging wherein wireless (13.56 MHz) power transmission is used to interlock the smart packaging with a wireless (13.56 MHz) reader or a smart phone. Assembly of the necessary componentry for smart packaging on plastic or paper foils is limited by the manufacturing costs involved with Si based technologies. Here, the issue of manufacturing cost for smart packaging has been obviated by materials that allow R2R (roll-to-roll) gravure in combination with R2R coating processes to be employed. R2R gravure was used to print the wireless power transmission device, called rectenna (antenna, diode and capacitor), and humidity sensor on poly(ethylene terephtalate) (PET) films while electrochromic signage units were fabricated by R2R coating. The signage units were laminated with the R2R gravure printed rectenna and sensor to complete the prototype smart packaging.

  6. Roll-to-Roll Encapsulation of Metal Nanowires between Graphene and Plastic Substrate for High-Performance Flexible Transparent Electrodes.

    PubMed

    Deng, Bing; Hsu, Po-Chun; Chen, Guanchu; Chandrashekar, B N; Liao, Lei; Ayitimuda, Zhawulie; Wu, Jinxiong; Guo, Yunfan; Lin, Li; Zhou, Yu; Aisijiang, Mahaya; Xie, Qin; Cui, Yi; Liu, Zhongfan; Peng, Hailin

    2015-06-10

    Transparent conductive film on plastic substrate is a critical component in low-cost, flexible, and lightweight optoelectronics. Industrial-scale manufacturing of high-performance transparent conductive flexible plastic is needed to enable wide-ranging applications. Here, we demonstrate a continuous roll-to-roll (R2R) production of transparent conductive flexible plastic based on a metal nanowire network fully encapsulated between graphene monolayer and plastic substrate. Large-area graphene film grown on Cu foil via a R2R chemical vapor deposition process was hot-laminated onto nanowires precoated EVA/PET film, followed by a R2R electrochemical delamination that preserves the Cu foil for reuse. The encapsulated structure minimized the resistance of both wire-to-wire junctions and graphene grain boundaries and strengthened adhesion of nanowires and graphene to plastic substrate, resulting in superior optoelectronic properties (sheet resistance of ∼8 Ω sq(-1) at 94% transmittance), remarkable corrosion resistance, and excellent mechanical flexibility. With these advantages, long-cycle life flexible electrochromic devices are demonstrated, showing up to 10000 cycles. PMID:26020567

  7. Roll-to-roll-compatible, flexible, transparent electrodes based on self-nanoembedded Cu nanowires using intense pulsed light irradiation.

    PubMed

    Zhong, Zhaoyang; Woo, Kyoohee; Kim, Inhyuk; Hwang, Hyewon; Kwon, Sin; Choi, Young-Man; Lee, Youngu; Lee, Taik-Min; Kim, Kwangyoung; Moon, Jooho

    2016-04-28

    Copper nanowire (Cu NW)-based flexible transparent conductive electrodes (FTCEs) have been investigated in detail for use in various applications such as flexible touch screens, organic photovoltaics and organic light-emitting diodes. In this study, hexadecylamine (HDA) adsorbed onto the surface of NWs is changed into polyvinylpyrrolidone (PVP) via a ligand exchange process; the high-molecular-weight PVP enables high dispersion stability. Intense pulsed light (IPL) irradiation is used to remove organic species present on the surface of the NWs and to form direct connections between the NWs rapidly without any atmospheric control. NWs are self-nanoembedded into a plastic substrate after IPL irradiation, which results in a smooth surface, strong NW/substrate adhesion, excellent mechanical flexibility and enhanced oxidation stability. Moreover, Cu NW FTCEs with high uniformities are successfully fabricated on a large area (150 mm × 200 mm) via successive IPL irradiation that is synchronized with the motion of the sample stage. This study demonstrates the possibility of roll-to-roll-based, large-scale production of low-cost, high-performance Cu NW-based FTCEs. PMID:27074548

  8. Fully roll-to-roll gravure printed rectenna on plastic foils for wireless power transmission at 13.56 MHz.

    PubMed

    Park, Hyejin; Kang, Hwiwon; Lee, Yonggil; Park, Yongsu; Noh, Jinsoo; Cho, Gyoujin

    2012-08-31

    Wireless power transmission to inexpensive and disposable smart electronic devices is one of the key issues for the realization of a ubiquitous society where sensor networks such as RFID tags, price tags, smart logos, signage and sensors could be fully interconnected and utilized by DC power of less than 0.3 W. This DC power can be provided by inductively coupled AC from a 13.56 MHz power transmitter through a rectenna, consisting of an antenna, a diode and a capacitor, which would be cheap to integrate with inexpensive smart electronic devices. To integrate the rectenna with a minimum cost, a roll-to-roll (R2R) gravure printing process has been considered to print the rectenna on plastic foils. In this paper, R2R gravure printing systems including printing condition and four different nanoparticle based inks will be reported to print the rectenna (antenna, diode and capacitor) on plastic foils at a printing speed of 8 m min(-1) and more than 90% device yield for a wireless power transmission of 0.3 W using a standard 13.56 MHz power transmitter. PMID:22885995

  9. Fully roll-to-roll gravure printable wireless (13.56 MHz) sensor-signage tags for smart packaging.

    PubMed

    Kang, Hwiwon; Park, Hyejin; Park, Yongsu; Jung, Minhoon; Kim, Byung Chul; Wallace, Gordon; Cho, Gyoujin

    2014-01-01

    Integration of sensing capabilities with an interactive signage through wireless communication is enabling the development of smart packaging wherein wireless (13.56 MHz) power transmission is used to interlock the smart packaging with a wireless (13.56 MHz) reader or a smart phone. Assembly of the necessary componentry for smart packaging on plastic or paper foils is limited by the manufacturing costs involved with Si based technologies. Here, the issue of manufacturing cost for smart packaging has been obviated by materials that allow R2R (roll-to-roll) gravure in combination with R2R coating processes to be employed. R2R gravure was used to print the wireless power transmission device, called rectenna (antenna, diode and capacitor), and humidity sensor on poly(ethylene terephtalate) (PET) films while electrochromic signage units were fabricated by R2R coating. The signage units were laminated with the R2R gravure printed rectenna and sensor to complete the prototype smart packaging. PMID:24953037

  10. Flexure-based Roll-to-roll Platform: A Practical Solution for Realizing Large-area Microcontact Printing

    PubMed Central

    Zhou, Xi; Xu, Huihua; Cheng, Jiyi; Zhao, Ni; Chen, Shih-Chi

    2015-01-01

    A continuous roll-to-roll microcontact printing (MCP) platform promises large-area nanoscale patterning with significantly improved throughput and a great variety of applications, e.g. precision patterning of metals, bio-molecules, colloidal nanocrystals, etc. Compared with nanoimprint lithography, MCP does not require a thermal imprinting step (which limits the speed and material choices), but instead, extreme precision with multi-axis positioning and misalignment correction capabilities for large area adaptation. In this work, we exploit a flexure-based mechanism that enables continuous MCP with 500 nm precision and 0.05 N force control. The fully automated roll-to-roll platform is coupled with a new backfilling MCP chemistry optimized for high-speed patterning of gold and silver. Gratings of 300, 400, 600 nm line-width at various locations on a 4-inch plastic substrate are fabricated at a speed of 60 cm/min. Our work represents the first example of roll-to-roll MCP with high reproducibility, wafer scale production capability at nanometer resolution. The precision roll-to-roll platform can be readily applied to other material systems. PMID:26037147

  11. Enabling large area and high throughput roll-to-roll NIL by novel inkjetable and photo-curable NIL resists

    NASA Astrophysics Data System (ADS)

    Thesen, Manuel W.; Rumler, Maximilian; Schlachter, Florian; Grützner, Susanne; Moormann, Christian; Rommel, Mathias; Nees, Dieter; Ruttloff, Stephan; Pfirrmann, Stefan; Vogler, Marko; Schleunitz, Arne; Grützner, Gabi

    2014-03-01

    The high throughput and large area nanostructuring of flexible substrates by continuous roller processes has great potential for future custom applications like wire grid polarizers, antireflection films, or super-hydrophobic surfaces. For each application different material characteristics have to be considered, e.g. refractive index, hydrophobicity, or dry etch stability. Herein, we show experimental results of nanoimprint lithography resist developments focused on inkjetable and photo-curable resists suitable for high throughput production, especially roll-to-roll NIL. The inkjet deposition of the novel materials is demonstrated by the use of different state-of-the-art inkjet printheads at room temperature. A plate-to-plate process on silicon substrates was successfully implemented on a NPS300 nano patterning stepper with previously inkjet dispensed NIL resist. Furthermore, we demonstrate a throughput of 30 m min-1 in a roller NIL process on PET. Dry etching of unstructured thin films on Si wafers was performed, and it was demonstrated that the etch stability in Si is tunable to a value of 3.5:1 by a concise selection of the resist components. The surface roughness of the etched films was measured to be < 2 nm, after etching of around 100 nm of the resist films what is an essential factor for a low line edge roughness. All resists reported herein can be deposited via inkjet dispensing at room temperature, are suitable for continuous high throughput imprinting on flexible substrates, and are applicable in step-wise NIL processes with good etch resistance in dry etch processes.

  12. Vacuum-thermal-evaporation: the route for roll-to-roll production of large-area organic electronic circuits

    NASA Astrophysics Data System (ADS)

    Taylor, D. M.

    2015-05-01

    Surprisingly little consideration is apparently being given to vacuum-evaporation as the route for the roll-to-roll (R2R) production of large-area organic electronic circuits. While considerable progress has been made by combining silicon lithographic approaches with solution processing, it is not obvious that these will be compatible with a low-cost, high-speed R2R process. Most efforts at achieving this ambition are directed at conventional solution printing approaches such as inkjet and gravure. This is surprising considering that vacuum-evaporation of organic semiconductors (OSCs) is already used commercially in the production of organic light emitting diode displays. Beginning from a discussion of the materials and geometrical parameters determining transistor performance and drawing on results from numerous publications, this review makes a case for vacuum-evaporation as an enabler of R2R organic circuit production. The potential of the vacuum route is benchmarked against solution approaches and found to be highly competitive. For example, evaporated small molecules tend to have higher mobility than printed OSCs. High resolution metal patterning on plastic films is already a low-cost commercial process for high-volume packaging applications. Similarly, solvent-free flash-evaporation and polymerization of thin films on plastic substrates is also a high-volume commercial process and has been shown capable of producing robust gate dielectrics. Reports of basic logic circuit elements produced in a vacuum R2R environment are reviewed and shown to be superior to all-solution printing approaches. Finally, the main issues that need to be resolved in order to fully develop the vacuum route to R2R circuit production are highlighted.

  13. Continuous roll-to-roll a-Si photovoltaic manufacturing technology

    SciTech Connect

    Izu, M. )

    1993-04-01

    This report describes work performed by ECD to advance its roll-to-roll, triple-junction photovoltaic manufacturing technologies; to reduce the module production costs; to increase the stabilized module performance; and to expand the commercial capacity utilizing ECD technology. The 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD's earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1/W[sub p]. Major efforts during Phase I are (1) the optimization of the high-performance back-reflector system, (2) the optimization of a-Si-Ge narrow band-gap solar cell, and (3) the optimization of the stable efficiency of the module. The goal is to achieve a stable 8% efficient 0.3-m [times] 1.2-m (1-ft [times] 4-ft) module. Also, the efforts include work on a proprietary, high-deposition-rate, microwave plasma, CVD manufacturing technology; and on the investigation of material cost reduction.

  14. Reduced Blood Coagulation on Roll-to-Roll, Shrink-Induced Superhydrophobic Plastics.

    PubMed

    Nokes, Jolie M; Liedert, Ralph; Kim, Monica Y; Siddiqui, Ali; Chu, Michael; Lee, Eugene K; Khine, Michelle

    2016-03-01

    The unique antiwetting properties of superhydrophobic (SH) surfaces prevent the adhesion of water and bodily fluids, including blood, urine, and saliva. While typical manufacturable approaches to create SH surfaces rely on chemical and structural modifications, such approaches are expensive, require postprocessing, and are often not biocompatible. By contrast, it is demonstrated that purely structural SH features are easily formed using high throughput roll-to-roll (R2R) manufacturing by shrinking a prestressed thermoplastic with a thin, stiff layer of silver and calcium. These features are subsequently embossed into any commercially available and Food and Drug Administration (FDA)-approved plastic. The R2R SH surfaces have contact angles >150° and contact angle hysteresis <10°. Importantly, the surfaces minimize blood adhesion, leading to reduced blood coagulation without the need for anticoagulants. SH surfaces have >4200× reduction of blood residue area compared to the nonstructured controls of the same material. In addition, blood clotting is reduced >5× using whole blood directly from the patient. Furthermore, these surfaces can be easily configured into 3D shapes, as demonstrated with SH tubes. With the simple scale-up production and the eliminated need for anticoagulants to prevent clotting, the proposed conformable SH surfaces can be impactful for a wide range of medical tools, including catheters and microfluidic channels. PMID:26784916

  15. Shear-induced dry transfer of reduced graphene oxide thin film via roll-to-roll printing

    NASA Astrophysics Data System (ADS)

    Jang, Hyun-woo; Kim, Woo Soo

    2016-02-01

    Here, we report a printing mechanism that utilizes mechanical stress for dry transfer of chemically reduced graphene oxide (r-GO) thin film. We discover that shear stress induced on the elastomeric stamp surface facilitates delamination of the deposited r-GO thin film from the stamp. Shear stress is introduced in a roll-to-roll printing system by rotating the stamp roller faster than the substrate roller. Energy-balance theory for thin film transfer is suggested to analyze the film delamination behavior with induced shear stress. Facile dry transfer of r-GO thin film onto flexible substrates is demonstrated in a roll-to-roll printing system at a printing rate of 5 mm/min with calculated shear stress of 325.43 kPa.

  16. Continuous roll-to-roll amorphous silicon photovoltaic manufacturing technology. Semiannual subcontract report, 1 April 1993--30 September 1993

    SciTech Connect

    Izu, M.

    1994-06-01

    This report describes work for this reporting period under a 3-year program to advance Energy Conversion Device`s (ECD) roll-to-roll, triple-junction photovoltaic (PV) manufacturing technologies, to reduce the module production costs, to increase the stabilized module performance, and to expand commercial production capacity utilizing ECD technology. The specific 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD`s earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1.00 per peak watt. Major accomplishments during this reporting period include (1) the design, construction. amd testomg of a continuous roll-to-roll multipurpose amorphous silicon alloy solar cell deposition machine that incorporates improvements necessary to obtain higher efficiency solar cells; (2) development of a photothermal deflection spectroscopy (PDS) technique for evaluating back-reflector systems; (3) the development of an improved textured Ag/ZnO back-reflector system demonstrating 25% gain in J{sub sc} over previous textured Al back-reflector systems; and (4) the design of a serpentine web continuous roll-to-roll deposition chamber.

  17. Fabrication of flexible oriented magnetic thin films with large in-plane uniaxial anisotropy by roll-to-roll nanoimprint lithography

    NASA Astrophysics Data System (ADS)

    Thantirige, Rukshan M.; John, Jacob; Pradhan, Nihar R.; Carter, Kenneth R.; Tuominen, Mark T.

    2016-06-01

    Here, we report wafer scale fabrication of densely packed Fe nanostripe-based magnetic thin films on a flexible substrate and their magnetic anisotropy properties. We find that Fe nanostripes exhibit large in-plane uniaxial anisotropy and nearly square hysteresis loops with energy products (BHmax) exceeding 3 MGOe at room temperature. High density Fe nanostripes were fabricated on 70 nm flexible polyethylene terephthalate (PET) gratings, which were made by a roll-to-roll (R2R) UV nanoimprint lithography technique. We observed large in-plane uniaxial anisotropies along the long dimension of nanostripes that can be attributed to the shape. Temperature dependent hysteresis measurements confirm that the magnetization reversal is driven by non-coherent rotation reversal processes.

  18. Direct and precise measurement of displacement and velocity of flexible web in roll-to-roll manufacturing systems.

    PubMed

    Kang, Dongwoo; Kim, Young duk; Lee, Eonseok; Choi, Young-Man; Lee, Taik-Min; Kim, Dongmin

    2013-12-01

    Interest in the production of printed electronics using a roll-to-roll system has gradually increased due to its low mass-production costs and compatibility with flexible substrate. To improve the accuracy of roll-to-roll manufacturing systems, the movement of the web needs to be measured precisely in advance. In this paper, a novel measurement method is developed to measure the displacement and velocity of the web precisely and directly. The proposed algorithm is based on the traditional single field encoder principle, and the scale grating has been replaced with a printed grating on the web. Because a printed grating cannot be as accurate as a scale grating in a traditional encoder, there will inevitably be variations in pitch and line-width, and the motion of the web should be measured even though there are variations in pitch and line-width in the printed grating patterns. For this reason, the developed algorithm includes a precise method of estimating the variations in pitch. In addtion, a method of correcting the Lissajous curve is presented for precision phase interpolation to improve measurement accuracy by correcting Lissajous circle to unit circle. The performance of the developed method is evaluated by simulation and experiment. In the experiment, the displacement error was less than 2.5 μm and the velocity error of 1σ was about 0.25%, while the grating scale moved 30 mm. PMID:24387460

  19. Direct and precise measurement of displacement and velocity of flexible web in roll-to-roll manufacturing systems

    SciTech Connect

    Kang, Dongwoo; Lee, Eonseok; Choi, Young-Man; Lee, Taik-Min; Kim, Duk Young; Kim, Dongmin

    2013-12-15

    Interest in the production of printed electronics using a roll-to-roll system has gradually increased due to its low mass-production costs and compatibility with flexible substrate. To improve the accuracy of roll-to-roll manufacturing systems, the movement of the web needs to be measured precisely in advance. In this paper, a novel measurement method is developed to measure the displacement and velocity of the web precisely and directly. The proposed algorithm is based on the traditional single field encoder principle, and the scale grating has been replaced with a printed grating on the web. Because a printed grating cannot be as accurate as a scale grating in a traditional encoder, there will inevitably be variations in pitch and line-width, and the motion of the web should be measured even though there are variations in pitch and line-width in the printed grating patterns. For this reason, the developed algorithm includes a precise method of estimating the variations in pitch. In addtion, a method of correcting the Lissajous curve is presented for precision phase interpolation to improve measurement accuracy by correcting Lissajous circle to unit circle. The performance of the developed method is evaluated by simulation and experiment. In the experiment, the displacement error was less than 2.5 μm and the velocity error of 1σ was about 0.25%, while the grating scale moved 30 mm.

  20. Roll-To-Roll Process for Transparent Metal Electrodes in OLED Manufacturing

    SciTech Connect

    Slafer, W. Dennis

    2010-06-02

    This program will develop and demonstrate a new manufacturing technology that can help to improve the efficiency and reduce the cost of producing the next generation solid-state lighting (OLEDs)for a broad range of commercial applications. This will not only improve US competitiveness in the manufacturing sector but will also result in a positive impact in meeting the Department of Energy’s goal of developing high efficiency lighting while reducing the environmental impact.

  1. Flexible indium zinc oxide/Ag/indium zinc oxide multilayer electrode grown on polyethersulfone substrate by cost-efficient roll-to-roll sputtering for flexible organic photovoltaics

    SciTech Connect

    Park, Yong-Seok; Kim, Han-Ki

    2010-01-15

    The authors describe the preparation and characteristics of flexible indium zinc oxide (IZO)-Ag-IZO multilayer electrodes grown on flexible polyethersulfone (PES) substrates using a roll-to-roll sputtering system for use in flexible organic photovoltaics. By the continuous roll-to-roll sputtering of the bottom IZO, Ag, and top IZO layers at room temperature, they were able to fabricate a high quality IZO-Ag-IZO multilayer electrode with a sheet resistance of 6.15 {epsilon}/square, optical transmittance of 87.4%, and figure of merit value of 42.03x10{sup -3} {Omega}{sup -1} on the PES substrate. In addition, the IZO-Ag-IZO multilayer electrode exhibited superior flexibility to the roll-to-roll sputter grown single ITO electrode due to the existence of a ductile Ag layer between the IZO layers and stable amorphous structure of the IZO film. Furthermore, the flexible organic solar cells (OSCs) fabricated on the roll-to-roll sputter grown IZO-Ag-IZO electrode showed higher power efficiency (3.51%) than the OSCs fabricated on the roll-to-roll sputter grown single ITO electrode (2.67%).

  2. Experimental investigation on the large-area fabrication of micro-pyramid arrays by roll-to-roll hot embossing on PVC film

    NASA Astrophysics Data System (ADS)

    Deng, Yujun; Yi, Peiyun; Peng, Linfa; Lai, Xinmin; Lin, Zhongqin

    2014-04-01

    Large-area polymeric components with micro-pyramids have been widely applied in the fields of optics, optoelectronics, biology and chemistry, etc. Roll-to-roll (R2R) hot embossing is regarded as a promising approach to fulfil high throughput fabrication of patterned polymeric films. In this study, an R2R hot embossing system has been developed in-house and effective and continuous production of the polymeric component with micro-pyramids is demonstrated by R2R hot embossing. The influence of processing parameters has been firstly investigated by using the one-variable-at-a-time method. Afterwards, a series of experiments based on the central composite design approach have been conducted for the analysis of variance and the establishment of empirical models of the R2R hot embossing process. As a result, a 90 mm × 90 mm PVC sample with a feature height of 65 µm was successfully fabricated and the height consistency reached 94.5%. Additionally, a process window with a mold temperature of 150-160 °C, an applied force of 18-25 kgf and a feeding speed of 0.3-0.5 m min-1, was established to achieve 100% passable micro-pyramid arrays. The processing rules and the concrete ranges of parameter values can guide the process production of large-area micro-pyramids.

  3. Roll-to-roll fabrication of large scale and regular arrays of three-dimensional nanospikes for high efficiency and flexible photovoltaics

    NASA Astrophysics Data System (ADS)

    Leung, Siu-Fung; Gu, Leilei; Zhang, Qianpeng; Tsui, Kwong-Hoi; Shieh, Jia-Min; Shen, Chang-Hong; Hsiao, Tzu-Hsuan; Hsu, Chin-Hung; Lu, Linfeng; Li, Dongdong; Lin, Qingfeng; Fan, Zhiyong

    2014-03-01

    Three-dimensional (3-D) nanostructures have demonstrated enticing potency to boost performance of photovoltaic devices primarily owning to the improved photon capturing capability. Nevertheless, cost-effective and scalable fabrication of regular 3-D nanostructures with decent robustness and flexibility still remains as a challenging task. Meanwhile, establishing rational design guidelines for 3-D nanostructured solar cells with the balanced electrical and optical performance are of paramount importance and in urgent need. Herein, regular arrays of 3-D nanospikes (NSPs) were fabricated on flexible aluminum foil with a roll-to-roll compatible process. The NSPs have precisely controlled geometry and periodicity which allow systematic investigation on geometry dependent optical and electrical performance of the devices with experiments and modeling. Intriguingly, it has been discovered that the efficiency of an amorphous-Si (a-Si) photovoltaic device fabricated on NSPs can be improved by 43%, as compared to its planar counterpart, in an optimal case. Furthermore, large scale flexible NSP solar cell devices have been fabricated and demonstrated. These results not only have shed light on the design rules of high performance nanostructured solar cells, but also demonstrated a highly practical process to fabricate efficient solar panels with 3-D nanostructures, thus may have immediate impact on thin film photovoltaic industry.

  4. Roll-to-roll fabrication of large scale and regular arrays of three-dimensional nanospikes for high efficiency and flexible photovoltaics.

    PubMed

    Leung, Siu-Fung; Gu, Leilei; Zhang, Qianpeng; Tsui, Kwong-Hoi; Shieh, Jia-Min; Shen, Chang-Hong; Hsiao, Tzu-Hsuan; Hsu, Chin-Hung; Lu, Linfeng; Li, Dongdong; Lin, Qingfeng; Fan, Zhiyong

    2014-01-01

    Three-dimensional (3-D) nanostructures have demonstrated enticing potency to boost performance of photovoltaic devices primarily owning to the improved photon capturing capability. Nevertheless, cost-effective and scalable fabrication of regular 3-D nanostructures with decent robustness and flexibility still remains as a challenging task. Meanwhile, establishing rational design guidelines for 3-D nanostructured solar cells with the balanced electrical and optical performance are of paramount importance and in urgent need. Herein, regular arrays of 3-D nanospikes (NSPs) were fabricated on flexible aluminum foil with a roll-to-roll compatible process. The NSPs have precisely controlled geometry and periodicity which allow systematic investigation on geometry dependent optical and electrical performance of the devices with experiments and modeling. Intriguingly, it has been discovered that the efficiency of an amorphous-Si (a-Si) photovoltaic device fabricated on NSPs can be improved by 43%, as compared to its planar counterpart, in an optimal case. Furthermore, large scale flexible NSP solar cell devices have been fabricated and demonstrated. These results not only have shed light on the design rules of high performance nanostructured solar cells, but also demonstrated a highly practical process to fabricate efficient solar panels with 3-D nanostructures, thus may have immediate impact on thin film photovoltaic industry. PMID:24603964

  5. Transparent SiON/Ag/SiON multilayer passivation grown on a flexible polyethersulfone substrate using a continuous roll-to-roll sputtering system

    PubMed Central

    2012-01-01

    We have investigated the characteristics of a silicon oxynitride/silver/silicon oxynitride [SiON/Ag/SiON] multilayer passivation grown using a specially designed roll-to-roll [R2R] sputtering system on a flexible polyethersulfone substrate. Optical, structural, and surface properties of the R2R grown SiON/Ag/SiON multilayer were investigated as a function of the SiON thickness at a constant Ag thickness of 12 nm. The flexible SiON/Ag/SiON multilayer has a high optical transmittance of 87.7% at optimized conditions due to the antireflection and surface plasmon effects in the oxide-metal-oxide structure. The water vapor transmission rate of the SiON/Ag/SiON multilayer is 0.031 g/m2 day at an optimized SiON thickness of 110 nm. This indicates that R2R grown SiON/Ag/SiON is a promising thin-film passivation for flexible organic light-emitting diodes and flexible organic photovoltaics due to its simple and low-temperature process. PMID:22221400

  6. Printed polymer photonic devices for optical interconnect systems

    NASA Astrophysics Data System (ADS)

    Subbaraman, Harish; Pan, Zeyu; Zhang, Cheng; Li, Qiaochu; Guo, L. J.; Chen, Ray T.

    2016-03-01

    Polymer photonic device fabrication usually relies on the utilization of clean-room processes, including photolithography, e-beam lithography, reactive ion etching (RIE) and lift-off methods etc, which are expensive and are limited to areas as large as a wafer. Utilizing a novel and a scalable printing process involving ink-jet printing and imprinting, we have fabricated polymer based photonic interconnect components, such as electro-optic polymer based modulators and ring resonator switches, and thermo-optic polymer switch based delay networks and demonstrated their operation. Specifically, a modulator operating at 15MHz and a 2-bit delay network providing up to 35.4ps are presented. In this paper, we also discuss the manufacturing challenges that need to be overcome in order to make roll-to-roll manufacturing practically viable. We discuss a few manufacturing challenges, such as inspection and quality control, registration, and web control, that need to be overcome in order to realize true implementation of roll-to-roll manufacturing of flexible polymer photonic systems. We have overcome these challenges, and currently utilizing our inhouse developed hardware and software tools, <10μm alignment accuracy at a 5m/min is demonstrated. Such a scalable roll-to-roll manufacturing scheme will enable the development of unique optoelectronic devices which can be used in a myriad of different applications, including communication, sensing, medicine, security, imaging, energy, lighting etc.

  7. Ultra-slim flexible glass for roll-to-roll electronic device fabrication

    NASA Astrophysics Data System (ADS)

    Garner, Sean; Glaesemann, Scott; Li, Xinghua

    2014-08-01

    As displays and electronics evolve to become lighter, thinner, and more flexible, the choice of substrate continues to be critical to their overall optimization. The substrate directly affects improvements in the designs, materials, fabrication processes, and performance of advanced electronics. With their inherent benefits such as surface quality, optical transmission, hermeticity, and thermal and dimensional stability, glass substrates enable high-quality and long-life devices. As substrate thicknesses are reduced below 200 μm, ultra-slim flexible glass continues to provide these inherent benefits to high-performance flexible electronics such as displays, touch sensors, photovoltaics, and lighting. In addition, the reduction in glass thickness also allows for new device designs and high-throughput, continuous manufacturing enabled by R2R processes. This paper provides an overview of ultra-slim flexible glass substrates and how they enable flexible electronic device optimization. Specific focus is put on flexible glass' mechanical reliability. For this, a combination of substrate design and process optimizations has been demonstrated that enables R2R device fabrication on flexible glass. Demonstrations of R2R flexible glass processes such as vacuum deposition, photolithography, laser patterning, screen printing, slot die coating, and lamination have been made. Compatibility with these key process steps has resulted in the first demonstration of a fully functional flexible glass device fabricated completely using R2R processes.

  8. A disposable, roll-to-roll hot-embossed inertial microfluidic device for size-based sorting of microbeads and cells.

    PubMed

    Wang, Xiao; Liedert, Christina; Liedert, Ralph; Papautsky, Ian

    2016-05-21

    Inertial microfluidics has been a highly active area of research in recent years for high-throughput focusing and sorting of synthetic and biological microparticles. However, existing inertial microfluidic devices always rely on microchannels with high-aspect-ratio geometries (channel width w < channel height h) and small cross-sections (w×h < 50 × 100 μm(2)). Such deep and small structures increase fabrication difficulty and can limit manufacturing by large-scale and high-throughput production approaches such as roll-to-roll (R2R) hot embossing. In this work, we present a novel inertial microfluidic device using only a simple and low-aspect-ratio (LAR) straight microchannel (w > h) to achieve size-based sorting of microparticles and cells. The simple LAR geometry of the device enables successful high-throughput fabrication using R2R hot embossing. With optimized flow conditions and channel dimensions, we demonstrate continuous sorting of a mixture of 15 μm and 10 μm diameter microbeads with >97% sorting efficiency using the low-cost and disposable R2R chip. We further demonstrate size-based sorting of bovine white blood cells, demonstrating the ability to process real cellular samples in our R2R chip. We envision that this R2R hot-embossed inertial microfluidic chip will serve as a powerful yet low-cost and disposable tool for size-based sorting of synthetic microparticles in industrial applications or cellular samples in cell biology research and clinical diagnostics. PMID:27050341

  9. Millimeter Thin and Rubber-Like Solid-State Lighting Modules Fabricated Using Roll-to-Roll Fluidic Self-Assembly and Lamination.

    PubMed

    Park, Se-Chul; Biswas, Shantonu; Fang, Jun; Mozafari, Mahsa; Stauden, Thomas; Jacobs, Heiko O

    2015-06-24

    A millimeter thin rubber-like solid-state lighting module is reported. The fabrication of the lighting module incorporates assembly and electrical connection of light-emitting diodes (LEDs). The assembly is achieved using a roll-to-roll fluidic self-assembly. The LEDs are sandwiched in-between a stretchable top and bottom electrode to relieve the mechanical stress. The top contact is realized using a lamination technique that eliminates wire-bonding. PMID:25966304

  10. All-solution processed polymer light-emitting diode displays

    NASA Astrophysics Data System (ADS)

    Zheng, Hua; Zheng, Yina; Liu, Nanliu; Ai, Na; Wang, Qing; Wu, Sha; Zhou, Junhong; Hu, Diangang; Yu, Shufu; Han, Shaohu; Xu, Wei; Luo, Chan; Meng, Yanhong; Jiang, Zhixiong; Chen, Yawen; Li, Dongyun; Huang, Fei; Wang, Jian; Peng, Junbiao; Cao, Yong

    2013-06-01

    Adopting the emerging technology of printed electronics in manufacturing novel ultrathin flat panel displays attracts both academic and industrial interests because of the challenge in the device physics and the potential of reducing production costs. Here we produce all-solution processed polymer light-emitting diode displays by solution-depositing the cathode and utilizing a multifunctional buffer layer between the cathode and the organic layers. The use of ink-jetted conducting nanoparticles as the cathode yields high-resolution cathode patterns without any mechanical stress on the organic layers. The buffer layer, which offers the functions of solvent-proof electron injection and proper affinity, is fabricated by mixing the water/alcohol-soluble polymer and a curable epoxy adhesive. Our 1.5-inch polymer light-emitting diode displays are fabricated without any dead pixels or dead lines. The all-solution process eliminates the need for high vacuum for thermal evaporation of the cathode, which paves the way to industrial roll-to-roll manufacturing of flat panel displays.

  11. All-solution processed polymer light-emitting diode displays.

    PubMed

    Zheng, Hua; Zheng, Yina; Liu, Nanliu; Ai, Na; Wang, Qing; Wu, Sha; Zhou, Junhong; Hu, Diangang; Yu, Shufu; Han, Shaohu; Xu, Wei; Luo, Chan; Meng, Yanhong; Jiang, Zhixiong; Chen, Yawen; Li, Dongyun; Huang, Fei; Wang, Jian; Peng, Junbiao; Cao, Yong

    2013-01-01

    Adopting the emerging technology of printed electronics in manufacturing novel ultrathin flat panel displays attracts both academic and industrial interests because of the challenge in the device physics and the potential of reducing production costs. Here we produce all-solution processed polymer light-emitting diode displays by solution-depositing the cathode and utilizing a multifunctional buffer layer between the cathode and the organic layers. The use of ink-jetted conducting nanoparticles as the cathode yields high-resolution cathode patterns without any mechanical stress on the organic layers. The buffer layer, which offers the functions of solvent-proof electron injection and proper affinity, is fabricated by mixing the water/alcohol-soluble polymer and a curable epoxy adhesive. Our 1.5-inch polymer light-emitting diode displays are fabricated without any dead pixels or dead lines. The all-solution process eliminates the need for high vacuum for thermal evaporation of the cathode, which paves the way to industrial roll-to-roll manufacturing of flat panel displays. PMID:23736123

  12. Transition from Townsend to radio-frequency homogeneous dielectric barrier discharge in a roll-to-roll configuration

    NASA Astrophysics Data System (ADS)

    Bazinette, R.; Paillol, J.; Massines, F.

    2016-06-01

    The aim of this paper is to better understand the transition from Townsend to radio-frequency homogeneous dielectric barrier discharge (DBD) at atmospheric pressure. The study is done in an Ar/NH3 Penning mixture for an electrode configuration adapted to roll-to-roll plasma surface treatment. The study was led in a frequency range running from 50 kHz up to 8.3 MHz leading to different DBD modes with a 1 mm gas gap: Glow (GDBD), Townsend (TDBD), and Radio-frequency (RF-DBD). In the frequency range between TDBD and RF-DBD, from 250 kHz to 2.3 MHz, additional discharges are observed outside the inter-electrode gas gap. Because each high voltage electrode are inside a dielectric barrel, these additional discharges occur on the side of the barrel where the gap is larger. They disappear when the RF-DBD mode is attained in the 1 mm inter-electrode gas gap, i.e., for frequencies equal or higher than 3 MHz. Fast imaging and optical emission spectroscopy show that the additional discharges are radio-frequency DBDs while the inter-electrode discharge is a TDBD. The RF-DBD discharge mode is attained when electrons drift becomes low enough compared to the voltage oscillation frequency to limit electron loss at the anode. To check that the additional discharges are due to a larger gas gap and a lower voltage amplitude, the TDBD/RF-DBD transition is investigated as a function of the gas gap and the applied voltage frequency and amplitude. Results show that the increase in the frequency at constant gas gap or in the gas gap at constant frequency allows to obtain RF-DBD instead of TDBD. At low frequency and large gap, the increase in the applied voltage allows RF-DBD/TDBD transition. As a consequence, an electrode configuration allowing different gap values is a solution to successively have different discharge modes with the same applied voltage.

  13. Roll-to-roll, shrink-induced superhydrophobic surfaces for antibacterial applications, enhanced point-of-care detection, and blood anticoagulation

    NASA Astrophysics Data System (ADS)

    Nokes, Jolie McLane

    Superhydrophobic (SH) surfaces are desirable because of their unique anti-wetting behavior. Fluid prefers to bead up (contact angle >150°) and roll off (contact angle hysteresis <10°) a SH surface because micro- and nanostructure features trap air pockets. Fluid only adheres to the peaks of the structures, causing minimal adhesion to the surface. Here, shrink-induced SH plastics are fabricated for a plethora of applications, including antibacterial applications, enhanced point-of-care (POC) detection, and reduced blood coagulation. Additionally, these purely structural SH surfaces are achieved in a roll-to-roll (R2R) platform for scalable manufacturing. Because their self-cleaning and water resistant properties, structurally modified SH surfaces prohibit bacterial growth and obviate bacterial chemical resistance. Antibacterial properties are demonstrated in a variety of SH plastics by preventing gram-negative Escherichia coli (E. coli) bacterial growth >150x compared to flat when fluid is rinsed and >20x without rinsing. Therefore, a robust and stable means to prevent bacteria growth is possible. Next, protein in urine is detected using a simple colorimetric output by evaporating droplets on a SH surface. Contrary to evaporation on a flat surface, evaporation on a SH surface allows fluid to dramatically concentrate because the weak adhesion constantly decreases the footprint area. On a SH surface, molecules in solution are confined to a footprint area 8.5x smaller than the original. By concentrating molecules, greater than 160x improvements in detection sensitivity are achieved compared to controls. Utility is demonstrated by detecting protein in urine in the pre-eclampsia range (150-300microgmL -1) for pregnant women. Further, SH surfaces repel bodily fluids including blood, urine, and saliva. Importantly, the surfaces minimize blood adhesion, leading to reduced blood coagulation without the need for anticoagulants. SH surfaces have >4200x and >28x reduction of

  14. Dynamics of the atmospheric pressure diffuse dielectric barrier discharge between cylindrical electrodes in roll-to-roll PECVD reactor

    NASA Astrophysics Data System (ADS)

    Starostin, Sergey A.; Welzel, Stefan; Liu, Yaoge; van der Velden-Schuermans, Bernadette; Bouwstra, Jan B.; van de Sanden, Mauritius C. M.; de Vries, Hindrik W.

    2015-07-01

    The high current diffuse dielectric barrier discharge (DBD) was operated in a bi-axial cylindrical electrode configuration using nitrogen, oxygen and argon gas flow with the addition of tetraethyl orthosilicate as precursor for silica-like film deposition. The behaviour of the transient plasma was visualized by means of fast imaging from two orthogonal directions. The formation and propagation (~3 × 104 m s-1) of lateral ionization waves with the transverse light emission structure similar to the low pressure glow discharge was observed at time scales below 1 µs. Despite plasma non-uniformity at nanosecond time scale the deposition process on the web-rolled polymer results in smooth well adherent films with good film uniformity and excellent gas diffusion barrier properties. Contribution to the topical issue "The 14th International Symposium on High Pressure Low Temperature Plasma Chemistry (HAKONE XIV)", edited by Nicolas Gherardi, Ronny Brandenburg and Lars Stollenwark

  15. Metrology challenges for high-rate nanomanufacturing of polymer structures

    NASA Astrophysics Data System (ADS)

    Mead, Joey; Barry, Carol; Busnaina, Ahmed; Isaacs, Jacqueline

    2012-10-01

    The transfer of nanoscience accomplishments into commercial products is hindered by the lack of understanding of barriers to nanoscale manufacturing. We have developed a number of nanomanufacturing processes that leverage available high-rate plastics fabrication technologies. These processes include directed assembly of a variety of nanoelements, such as nanoparticles and nanotubes, which are then transferred onto a polymer substrate for the fabrication of conformal/flexible electronic materials, among other applications. These assembly processes utilize both electric fields and/or chemical functionalization. Conducting polymers and carbon nanotubes have been successfully transferred to a polymer substrate in times less than 5 minutes, which is commercially relevant and can be utilized in a continuous (reel to reel/roll to roll) process. Other processes include continuous high volume mixing of nanoelements (CNTs, etc) into polymers, multi-layer extrusion and 3D injection molding of polymer structures. These nanomanufacturing processes can be used for wide range of applications, including EMI shielding, flexible electronics, structural materials, and novel sensors (specifically for chem/bio detection). Current techniques to characterize the quality and efficacy of the processes are quite slow. Moreover, the instrumentation and metrology needs for these manufacturing processes are varied and challenging. Novel, rapid, in-line metrology to enable the commercialization of these processes is critically needed. This talk will explore the necessary measurement needs for polymer based nanomanufacturing processes for both step and continuous (reel to reel/roll to roll) processes.

  16. Ultrafast formation of air-processable and high-quality polymer films on an aqueous substrate.

    PubMed

    Noh, Jonghyeon; Jeong, Seonju; Lee, Jung-Yong

    2016-01-01

    Polymer solar cells are attracting attention as next-generation energy sources. Scalable deposition techniques of high-quality organic films should be guaranteed to realize highly efficient polymer solar cells in large areas for commercial viability. Herein, we introduce an ultrafast, scalable, and versatile process for forming high-quality organic films on an aqueous substrate by utilizing the spontaneous spreading phenomenon. This approach provides easy control over the thickness of the films by tuning the spreading conditions, and the films can be transferred to a variety of secondary substrates. Moreover, the controlled Marangoni flow and ultrafast removal of solvent during the process cause the films to have a uniform, high-quality nanomorphology with finely separated phase domains. Polymer solar cells were fabricated from a mixture of polymer and fullerene derivatives on an aqueous substrate by using the proposed technique, and the device exhibited an excellent power conversion efficiency of 8.44 %. Furthermore, a roll-to-roll production system was proposed as an air-processable and scalable commercial process for fabricating organic devices. PMID:27507624

  17. Ultrafast formation of air-processable and high-quality polymer films on an aqueous substrate

    NASA Astrophysics Data System (ADS)

    Noh, Jonghyeon; Jeong, Seonju; Lee, Jung-Yong

    2016-08-01

    Polymer solar cells are attracting attention as next-generation energy sources. Scalable deposition techniques of high-quality organic films should be guaranteed to realize highly efficient polymer solar cells in large areas for commercial viability. Herein, we introduce an ultrafast, scalable, and versatile process for forming high-quality organic films on an aqueous substrate by utilizing the spontaneous spreading phenomenon. This approach provides easy control over the thickness of the films by tuning the spreading conditions, and the films can be transferred to a variety of secondary substrates. Moreover, the controlled Marangoni flow and ultrafast removal of solvent during the process cause the films to have a uniform, high-quality nanomorphology with finely separated phase domains. Polymer solar cells were fabricated from a mixture of polymer and fullerene derivatives on an aqueous substrate by using the proposed technique, and the device exhibited an excellent power conversion efficiency of 8.44 %. Furthermore, a roll-to-roll production system was proposed as an air-processable and scalable commercial process for fabricating organic devices.

  18. Ultrafast formation of air-processable and high-quality polymer films on an aqueous substrate

    PubMed Central

    Noh, Jonghyeon; Jeong, Seonju; Lee, Jung-Yong

    2016-01-01

    Polymer solar cells are attracting attention as next-generation energy sources. Scalable deposition techniques of high-quality organic films should be guaranteed to realize highly efficient polymer solar cells in large areas for commercial viability. Herein, we introduce an ultrafast, scalable, and versatile process for forming high-quality organic films on an aqueous substrate by utilizing the spontaneous spreading phenomenon. This approach provides easy control over the thickness of the films by tuning the spreading conditions, and the films can be transferred to a variety of secondary substrates. Moreover, the controlled Marangoni flow and ultrafast removal of solvent during the process cause the films to have a uniform, high-quality nanomorphology with finely separated phase domains. Polymer solar cells were fabricated from a mixture of polymer and fullerene derivatives on an aqueous substrate by using the proposed technique, and the device exhibited an excellent power conversion efficiency of 8.44 %. Furthermore, a roll-to-roll production system was proposed as an air-processable and scalable commercial process for fabricating organic devices. PMID:27507624

  19. Printed light-trapping nanorelief Cu electrodes for full-solution-processed flexible organic solar cells

    NASA Astrophysics Data System (ADS)

    Li, Kan; Zhang, Yaokang; Zhen, Hongyu; Niu, Liyong; Fang, Xu; Liu, Zhike; Yan, Feng; Shen, Weidong; Li, Haifeng; Zheng, Zijian

    2016-07-01

    Light-trapping nanorelief metal electrodes have been proven to be an effective approach to improve the absorption performance of flexible organic solar cells (FOSCs). These nanorelief electrodes have been made by conventional vacuum deposition techniques, which are difficult to integrate with roll-to-roll fabrication processes. To address this challenge, this paper reports, for the first time, the fabrication of highly conductive nanorelief Cu electrodes on the flexible substrates through solution printing and polymer-assisted metal deposition at room temperature in the air. FOSCs made with these printed nanorelief Cu electrodes possess not only much improved power conversion efficiency, by 13.5%, but also significant enhancement in flexibility when compared with those made with flat Cu electrodes. Because of the low material and fabrication cost, these printed nanorelief Cu electrodes show great promise in roll-to-roll fabrication of FOSCs in the future.

  20. Large-area perovskite nanowire arrays fabricated by large-scale roll-to-roll micro-gravure printing and doctor blading

    NASA Astrophysics Data System (ADS)

    Hu, Qiao; Wu, Han; Sun, Jia; Yan, Donghang; Gao, Yongli; Yang, Junliang

    2016-02-01

    Organic-inorganic hybrid halide perovskite nanowires (PNWs) show great potential applications in electronic and optoelectronic devices such as solar cells, field-effect transistors and photodetectors. It is very meaningful to fabricate ordered, large-area PNW arrays and greatly accelerate their applications and commercialization in electronic and optoelectronic devices. Herein, highly oriented and ultra-long methylammonium lead iodide (CH3NH3PbI3) PNW array thin films were fabricated by large-scale roll-to-roll (R2R) micro-gravure printing and doctor blading in ambient environments (humility ~45%, temperature ~28 °C), which produced PNW lengths as long as 15 mm. Furthermore, photodetectors based on these PNWs were successfully fabricated on both silicon oxide (SiO2) and flexible polyethylene terephthalate (PET) substrates and showed moderate performance. This study provides low-cost, large-scale techniques to fabricate large-area PNW arrays with great potential applications in flexible electronic and optoelectronic devices.Organic-inorganic hybrid halide perovskite nanowires (PNWs) show great potential applications in electronic and optoelectronic devices such as solar cells, field-effect transistors and photodetectors. It is very meaningful to fabricate ordered, large-area PNW arrays and greatly accelerate their applications and commercialization in electronic and optoelectronic devices. Herein, highly oriented and ultra-long methylammonium lead iodide (CH3NH3PbI3) PNW array thin films were fabricated by large-scale roll-to-roll (R2R) micro-gravure printing and doctor blading in ambient environments (humility ~45%, temperature ~28 °C), which produced PNW lengths as long as 15 mm. Furthermore, photodetectors based on these PNWs were successfully fabricated on both silicon oxide (SiO2) and flexible polyethylene terephthalate (PET) substrates and showed moderate performance. This study provides low-cost, large-scale techniques to fabricate large-area PNW arrays

  1. Large-area perovskite nanowire arrays fabricated by large-scale roll-to-roll micro-gravure printing and doctor blading.

    PubMed

    Hu, Qiao; Wu, Han; Sun, Jia; Yan, Donghang; Gao, Yongli; Yang, Junliang

    2016-02-25

    Organic-inorganic hybrid halide perovskite nanowires (PNWs) show great potential applications in electronic and optoelectronic devices such as solar cells, field-effect transistors and photodetectors. It is very meaningful to fabricate ordered, large-area PNW arrays and greatly accelerate their applications and commercialization in electronic and optoelectronic devices. Herein, highly oriented and ultra-long methylammonium lead iodide (CH3NH3PbI3) PNW array thin films were fabricated by large-scale roll-to-roll (R2R) micro-gravure printing and doctor blading in ambient environments (humility ∼45%, temperature ∼28 °C), which produced PNW lengths as long as 15 mm. Furthermore, photodetectors based on these PNWs were successfully fabricated on both silicon oxide (SiO2) and flexible polyethylene terephthalate (PET) substrates and showed moderate performance. This study provides low-cost, large-scale techniques to fabricate large-area PNW arrays with great potential applications in flexible electronic and optoelectronic devices. PMID:26883938

  2. Scalability of carbon-nanotube-based thin film transistors for flexible electronic devices manufactured using an all roll-to-roll gravure printing system

    PubMed Central

    Koo, Hyunmo; Lee, Wookyu; Choi, Younchang; Sun, Junfeng; Bak, Jina; Noh, Jinsoo; Subramanian, Vivek; Azuma, Yasuo; Majima, Yutaka; Cho, Gyoujin

    2015-01-01

    To demonstrate that roll-to-roll (R2R) gravure printing is a suitable advanced manufacturing method for flexible thin film transistor (TFT)-based electronic circuits, three different nanomaterial-based inks (silver nanoparticles, BaTiO3 nanoparticles and single-walled carbon nanotubes (SWNTs)) were selected and optimized to enable the realization of fully printed SWNT-based TFTs (SWNT-TFTs) on 150-m-long rolls of 0.25-m-wide poly(ethylene terephthalate) (PET). SWNT-TFTs with 5 different channel lengths, namely, 30, 80, 130, 180, and 230 μm, were fabricated using a printing speed of 8 m/min. These SWNT-TFTs were characterized, and the obtained electrical parameters were related to major mechanical factors such as web tension, registration accuracy, impression roll pressure and printing speed to determine whether these mechanical factors were the sources of the observed device-to-device variations. By utilizing the electrical parameters from the SWNT-TFTs, a Monte Carlo simulation for a 1-bit adder circuit, as a reference, was conducted to demonstrate that functional circuits with reasonable complexity can indeed be manufactured using R2R gravure printing. The simulation results suggest that circuits with complexity, similar to the full adder circuit, can be printed with a 76% circuit yield if threshold voltage (Vth) variations of less than 30% can be maintained. PMID:26411839

  3. Scalability of carbon-nanotube-based thin film transistors for flexible electronic devices manufactured using an all roll-to-roll gravure printing system

    NASA Astrophysics Data System (ADS)

    Koo, Hyunmo; Lee, Wookyu; Choi, Younchang; Sun, Junfeng; Bak, Jina; Noh, Jinsoo; Subramanian, Vivek; Azuma, Yasuo; Majima, Yutaka; Cho, Gyoujin

    2015-09-01

    To demonstrate that roll-to-roll (R2R) gravure printing is a suitable advanced manufacturing method for flexible thin film transistor (TFT)-based electronic circuits, three different nanomaterial-based inks (silver nanoparticles, BaTiO3 nanoparticles and single-walled carbon nanotubes (SWNTs)) were selected and optimized to enable the realization of fully printed SWNT-based TFTs (SWNT-TFTs) on 150-m-long rolls of 0.25-m-wide poly(ethylene terephthalate) (PET). SWNT-TFTs with 5 different channel lengths, namely, 30, 80, 130, 180, and 230 μm, were fabricated using a printing speed of 8 m/min. These SWNT-TFTs were characterized, and the obtained electrical parameters were related to major mechanical factors such as web tension, registration accuracy, impression roll pressure and printing speed to determine whether these mechanical factors were the sources of the observed device-to-device variations. By utilizing the electrical parameters from the SWNT-TFTs, a Monte Carlo simulation for a 1-bit adder circuit, as a reference, was conducted to demonstrate that functional circuits with reasonable complexity can indeed be manufactured using R2R gravure printing. The simulation results suggest that circuits with complexity, similar to the full adder circuit, can be printed with a 76% circuit yield if threshold voltage (Vth) variations of less than 30% can be maintained.

  4. Scalability of carbon-nanotube-based thin film transistors for flexible electronic devices manufactured using an all roll-to-roll gravure printing system.

    PubMed

    Koo, Hyunmo; Lee, Wookyu; Choi, Younchang; Sun, Junfeng; Bak, Jina; Noh, Jinsoo; Subramanian, Vivek; Azuma, Yasuo; Majima, Yutaka; Cho, Gyoujin

    2015-01-01

    To demonstrate that roll-to-roll (R2R) gravure printing is a suitable advanced manufacturing method for flexible thin film transistor (TFT)-based electronic circuits, three different nanomaterial-based inks (silver nanoparticles, BaTiO3 nanoparticles and single-walled carbon nanotubes (SWNTs)) were selected and optimized to enable the realization of fully printed SWNT-based TFTs (SWNT-TFTs) on 150-m-long rolls of 0.25-m-wide poly(ethylene terephthalate) (PET). SWNT-TFTs with 5 different channel lengths, namely, 30, 80, 130, 180, and 230 μm, were fabricated using a printing speed of 8 m/min. These SWNT-TFTs were characterized, and the obtained electrical parameters were related to major mechanical factors such as web tension, registration accuracy, impression roll pressure and printing speed to determine whether these mechanical factors were the sources of the observed device-to-device variations. By utilizing the electrical parameters from the SWNT-TFTs, a Monte Carlo simulation for a 1-bit adder circuit, as a reference, was conducted to demonstrate that functional circuits with reasonable complexity can indeed be manufactured using R2R gravure printing. The simulation results suggest that circuits with complexity, similar to the full adder circuit, can be printed with a 76% circuit yield if threshold voltage (Vth) variations of less than 30% can be maintained. PMID:26411839

  5. Air heating approach for multilayer etching and roll-to-roll transfer of silicon nanowire arrays as SERS substrates for high sensitivity molecule detection.

    PubMed

    Wang, Yan; Zhang, Xiujuan; Gao, Peng; Shao, Zhibin; Zhang, Xiwei; Han, Yuanyan; Jie, Jiansheng

    2014-01-22

    SiNW array represents an attractive system for construction of high-performance energy, electronic, and sensor devices. To meet the demand for flexible devices as well as address the concern about the full use of the Si material, large-area transfer of the SiNW array from growth substrate is very desirable. Here, we report a simple air heating approach to achieve the multilayer etched SiNW array. This method allows the fabrication of up to a five-layer (while perfectly three-layer) cracked SiNW array on single-crystalline Si wafer via a templateless metal-assisted etching approach. Fractures could happen at the crack position when an appropriate pressure was applied on the SiNW array, facilitating the wafer-scale layer-by-layer transfer of the SiNW array onto a flexible substrate through a low-cost and time-efficient roll-to-roll (R2R) technique. Further releasing of the SiNW array to other receiving substrates was accomplished with the aid of a thermal release tape. After modification with sliver nanoparticles (AgNPs), the flexible SiNW array showed great potential as a high-sensitivity surface-enhanced Raman spectroscopy (SERS) substrate for detecting rhodamine 6G (R6G) molecule with concentration as low as 10(-9) M. PMID:24377283

  6. Plasma and microwave flash sintering of a tailored silver nanoparticle ink, yielding 60% bulk conductivity on cost-effective polymer foils.

    PubMed

    Perelaer, Jolke; Jani, Robin; Grouchko, Michael; Kamyshny, Alexander; Magdassi, Shlomo; Schubert, Ulrich S

    2012-08-01

    A combination of plasma and microwave flash sintering is used to sinter an inkjet-printed and tailored silver nanoparticle formulation. By using two sintering techniques sequentially, the obtained conductivity is 60%, while keeping the processing temperature well below the glass transition temperature (T(g)) of the used polymer substrate. This approach leads to highly conductive features on cost-effective polymer substrates in relatively short times, which are compatible with roll-to-roll (R2R) production. An electroluminescence device is prepared as an example. PMID:22718319

  7. Processing of semicrystalline polymers

    NASA Technical Reports Server (NTRS)

    Cebe, Peggy; Brillhart, Mark V.

    1993-01-01

    Our research group has been interested in the processing-structure-property relationships in semicrystalline polymers and blends for many years. In situ real time x ray scattering at elevated temperatures is being used to monitor the development of structure. An ongoing collaboration with Dr. Malcolm Capel at the Brookhaven National Synchrotron Light Source allows the performance of real time wide and small angle x ray scattering to study the phase transformations in semicrystalline polymers. The first part of my presentation will be about our recent use of x ray scattering to study blends of poly(ethylene terephthalate) with polyarylates. The purpose of the next portion of the presentation is to show how we may study effects of self-deformation of polymers during processing in the gravity environment, using real time x ray scattering. In this way, how processing stresses alter the microstructure of semicrystalline polymers was learned, and ultimately microgravity processing strategies that will result in more uniform morphology in these polymers is hoped to be developed.

  8. Micro hot embossing of thermoplastic polymers: a review

    NASA Astrophysics Data System (ADS)

    Peng, Linfa; Deng, Yujun; Yi, Peiyun; Lai, Xinmin

    2014-01-01

    Micro hot embossing of thermoplastic polymers is a promising process to fabricate high precision and high quality features in micro/nano scale. This technology has experienced more than 40 years development and has been partially applied in industrial production. Three modes of micro hot embossing including plate-to-plate, roll-to-plate and roll-to-roll have been successively developed to meet the increasing demand for large-area patterned polymeric films. This review surveys recent progress of micro hot embossing in terms of polymeric material behavior, embossing process and corresponding apparatus. Besides, challenges and innovations in mold fabrication techniques are comprehensively summarized and industrial applications are systematically cataloged as well. Finally, technical challenges and future trends are presented for micro hot embossing of thermoplastic polymers.

  9. A Course in Polymer Processing.

    ERIC Educational Resources Information Center

    Soong, David S.

    1985-01-01

    A special-topics course in polymer processing has acquired regular course status. Course goals, content (including such new topics as polymer applications in microelectronics), and selected term projects are described. (JN)

  10. Processing polymers with cyclodextrins

    NASA Astrophysics Data System (ADS)

    Williamson, Brandon Robert

    Cyclodextrins (CDs) are cyclic starch molecules that have the unique ability to include a variety of small molecules and polymers inside their cavities, forming "Inclusion Complexes" (ICs). While much work has been done to understand the formation and behavior of these ICs, far less is known about the fundamental property changes that can occur when CD is used to alter polymer chain morphology. The goal of my graduate research has been to discover different ways to improve upon existing polymer properties through CD processing, as well as explore the possibility of creating a novel type of IC using non-traditional forms of cyclodextrin. Poly(ε-caprolactone) (PCL) was processed with alpha-CD to form an IC. The cyclodextrin was then stripped away to yield a PCL with elongated, unentangled, and constrained polymer chains, a process referred to as coalescence. The physical and rheological property changes resulting from this coalescence were then examined. It was found that reorganizing PCL in this manner resulted in an increase in the melt crystallization temperature of up to 25°C. Coalescence also decreased the tan delta of the material and increased the average hardness and Young's modulus by 33 and 53%, respectively. Non-stoichiometric ICs (NS-ICs), or ICs with at least parts of some polymer chains uncovered, were formed between poly (methyl methacrylate) (PMMA) and gamma-CD as well as a synthesized poly(ε-caprolactone)-poly(propylene glycol)-poly(ε-caprolactone) (PCL-PPG-PCL) triblock copolymer and beta-CD. The property changes of the non-complexed polymer chains were then studied. The PMMA/gamma-CD NS-IC samples were determined to be extremely heterogeneous, however glass transition temperature increases of up to 27°C above that of as-received PMMA were observed. Diffraction data for the PMMA NS-ICs suggests slight crystallinity at partial coverage, with a similar crystal structure to that of the fully covered IC. XRD, DSC and FTIR data revealed an almost

  11. FINAL REPORT: Transformational electrode drying process

    SciTech Connect

    Claus Daniel, C.; Wixom, M.

    2013-12-19

    This report includes major findings and outlook from the transformational electrode drying project performance period from January 6, 2012 to August 1, 2012. Electrode drying before cell assembly is an operational bottleneck in battery manufacturing due to long drying times and batch processing. Water taken up during shipment and other manufacturing steps needs to be removed before final battery assembly. Conventional vacuum ovens are limited in drying speed due to a temperature threshold needed to avoid damaging polymer components in the composite electrode. Roll to roll operation and alternative treatments can increase the water desorption and removal rate without overheating and damaging other components in the composite electrode, thus considerably reducing drying time and energy use. The objective of this project was the development of an electrode drying procedure, and the demonstration of processes with no decrease in battery performance. The benchmark for all drying data was an 80°C vacuum furnace treatment with a residence time of 18 – 22 hours. This report demonstrates an alternative roll to roll drying process with a 500-fold improvement in drying time down to 2 minutes and consumption of only 30% of the energy compared to vacuum furnace treatment.

  12. Monolithic amorphous silicon modules on continuous polymer substrate

    SciTech Connect

    Grimmer, D.P. )

    1992-03-01

    This report examines manufacturing monolithic amorphous silicon modules on a continuous polymer substrate. Module production costs can be reduced by increasing module performance, expanding production, and improving and modifying production processes. Material costs can be reduced by developing processes that use a 1-mil polyimide substrate and multilayers of low-cost material for the front encapsulant. Research to speed up a-Si and ZnO deposition rates is needed to improve throughputs. To keep throughput rates compatible with depositions, multibeam fiber optic delivery systems for laser scribing can be used. However, mechanical scribing systems promise even higher throughputs. Tandem cells and production experience can increase device efficiency and stability. Two alternative manufacturing processes are described: (1) wet etching and sheet handling and (2) wet etching and roll-to-roll fabrication.

  13. Top laminated graphene electrode in a semitransparent polymer solar cell by simultaneous thermal annealing/releasing method.

    PubMed

    Lee, Yu-Ying; Tu, Kun-Hua; Yu, Chen-Chieh; Li, Shao-Sian; Hwang, Jeong-Yuan; Lin, Chih-Cheng; Chen, Kuei-Hsien; Chen, Li-Chyong; Chen, Hsuen-Li; Chen, Chun-Wei

    2011-08-23

    In this article, we demonstrate a semitransparent inverted-type polymer solar cell using a top laminated graphene electrode without damaging the underlying organic photoactive layer. The lamination process involves the simultaneous thermal releasing deposition of the graphene top electrode during thermal annealing of the photoactive layer. The resulting semitransparent polymer solar cell exhibits a promising power conversion efficiency of approximately 76% of that of the standard opaque device using an Ag metal electrode. The asymmetric photovoltaic performances of the semitransparent solar cell while illuminated from two respective sides were further analyzed using optical simulation and photocarrier recombination measurement. The devices consisting of the top laminated transparent graphene electrode enable the feasible roll-to-roll manufacturing of low-cost semitransparent polymer solar cells and can be utilized in new applications such as power-generated windows or multijunction or bifacial photovoltaic devices. PMID:21749099

  14. In Situ Photocatalytically Heterostructured ZnO-Ag Nanoparticle Composites as Effective Cathode-Modifying Layers for Air-Processed Polymer Solar Cells.

    PubMed

    Yuan, Kai; Chen, Lie; Chen, Yiwang

    2015-08-10

    A heterostructured semiconductor-metal ZnO-Ag nanoparticle (NP) composite was constructed through a straightforward photocatalytic strategy by using UV irradiation of ZnO NPs and an aqueous solution of Ag precursor. The ZnO-Ag NP composites serve as an effective cathode-modifying layer in polymer solar cells (PSCs) with increased short-circuit current density owing to the light-trapping effect, and improved optical and electrical conductivity properties compared with pure ZnO NPs. The Ag NPs, which are photodeposited in situ on ZnO NPs, can act as effective antennas for incident light to maximize light harvesting and minimize radiative decay or nonradiative losses, consequently resulting in the enhanced photogeneration of excitons in PSCs. Systematic photoelectron and -physical investigations confirm that heterostructured ZnO-Ag NPs can significantly improve charge separation, transport, and collection, as well as lower charge recombination at the cathode interface, leading to a 14.0 % improvement in air-processed device power conversion efficiency. In addition, this processable, cost-effective, and scalable approach is compatible with roll-to-roll manufacturing of large-scale PSCs. PMID:26135916

  15. Effect of Ar Ion Beam Pre-Treatment of Poly(ethylene terephthalate) Substrate on the Mechanical and Electrical Stability of Flexible InSnO Films Grown by Roll-to-Roll Sputtering System

    NASA Astrophysics Data System (ADS)

    Choi, Kwang-Hyuk; Kim, Han-Ki

    2013-10-01

    We investigated the effects of Ar ion beam irradiation on a flexible poly(ethylene terephthalate) (PET) substrate as surface pre-treatment method in the roll-to-roll (R2R) sputtering system and its contribution to the electrical durability of flexible InSnO (ITO) electrode upon that the flexible PET substrate under repeated mechanical stresses. It was found that the Ar ion beam irradiation of the flexible PET surface could improve an adhesion between R2R sputter-grown ITO film and the PET substrate. X-ray photoelectron spectroscopy results showed that the Ar ion beam irradiation lead to an increase of hydrophilic functional groups when the working pressure, Ar ion beam power, and exposure time increases. Repetitive bending stresses for the flexible ITO/PET film which fabricated through the surface pre-treatment by Ar ion beam irradiation showed more stable electrical durability than those of ITO films on the wet-cleaned PET substrate due to enhanced interfacial adhesion between the ITO film and PET surface. This suggests that the Ar ion beam pre-treatment before sputtering of ITO film in R2R sputtering system is an effective technique to improve the adhesion between ITO film and PET substrate.

  16. Critical Issues for Cu(InGa)Se2 Solar Cells on Flexible Polymer Web

    NASA Technical Reports Server (NTRS)

    Eser, Erten; Fields, Shannon; Shafarman, William; Birkmire, Robert

    2007-01-01

    Elemental in-line evaporation on glass substrates has been a viable process for the large-area manufacture of CuInSe2-based photovoltaics, with module efficiencies as high as 12.7% [1]. However, lightweight, flexible CuInSe2-based modules are attractive in a number of applications, such as space power sources. In addition, flexible substrates have an inherent advantage in manufacturability in that they can be deposited in a roll-to-roll configuration allowing continuous, high yield, and ultimately lower cost production. As a result, high-temperature polymers have been used as substrates in depositing CuInSe2 films [2]. Recently, efficiency of 14.1% has been reported for a Cu(InGa)Se2-based solar cell on a polyimide substrate [3]. Both metal foil and polymer webs have been used as substrates for Cu(InGa)Se2-based photovoltaics in a roll-to-roll configuration with reasonable success [4,5]. Both of these substrates do not allow, readily, the incorporation of Na into the Cu(InGa)Se2 film which is necessary for high efficiency devices [3]. In addition, polymer substrates, can not be used at temperatures that are optimum for Cu(InGa)Se2 deposition. However, unlike metal foils, they are electrically insulating, simplifying monolithically-integrated module fabrication and are not a source of impurities diffusing into the growing film. The Institute of Energy Conversion (IEC) has modified its in-line evaporation system [6] from deposition onto glass substrates to roll-to-roll deposition onto polyimide (PI) film in order to investigate key issues in the deposition of large-area Cu(InGa)Se2 films on flexible polymer substrates. This transition presented unexpected challenges that had to be resolved. In this paper, two major problems, spitting from the Cu source and the cracking of Mo back contact film, will be discussed and the solution to each will be presented.

  17. Efficiency and throughput advances in continuous roll-to-roll a-Si alloy PV manufacturing technology: Annual technical progress report: 22 June 1998--21 June 1999

    SciTech Connect

    Izu, M.

    1999-11-09

    This document reports on work performed by Energy Conversion Devices, Inc. (ECD) during Phase 1 of this subcontract. During this period, ECD researchers: (1) Completed design and construction of new, improved substrate heater; (2) Tested and verified improved performance of the new substrate heater in the pilot machine; (3) Verified improved performance of the new substrate heater in the production machine; (4) Designed and bench-tested a new infrared temperature sensor; (5) Installed a prototype new infrared temperature sensor in the production machine for evaluation; (6) Designed a new rolling thermocouple temperature sensor; (7) Designed and bench-tested a reflectometer for the backreflector deposition machine; (8) Designed and bench-tested in-line non-contacting cell diagnostic sensor and PV capacitive diagnostic system; (9) Installed the in-line cell diagnostic sensor in the 5-MW a-Si deposition machine for evaluation; (10) Demonstrated a new low-cost zinc metal process in the pilot back reflector machine; and (11) Fully tested a new cathode design for improved uniformity.

  18. A Course in Polymer Processing.

    ERIC Educational Resources Information Center

    Soong, David S.

    1981-01-01

    Following a brief introduction to the origin and nature of a course in polymer rheology and melt processing, discusses course objectives, detailed content, teaching strategies, and observations/experiences from its first offering. (SK)

  19. Improving organic tandem solar cells based on water-processed nanoparticles by quantitative 3D nanoimaging.

    PubMed

    Pedersen, E B L; Angmo, D; Dam, H F; Thydén, K T S; Andersen, T R; Skjønsfjell, E T B; Krebs, F C; Holler, M; Diaz, A; Guizar-Sicairos, M; Breiby, D W; Andreasen, J W

    2015-08-28

    Organic solar cells have great potential for upscaling due to roll-to-roll processing and a low energy payback time, making them an attractive sustainable energy source for the future. Active layers coated with water-dispersible Landfester particles enable greater control of the layer formation and easier access to the printing industry, which has reduced the use of organic solvents since the 1980s. Through ptychographic X-ray computed tomography (PXCT), we image quantitatively a roll-to-roll coated photovoltaic tandem stack consisting of one bulk heterojunction active layer and one Landfester particle active layer. We extract the layered morphology with structural and density information including the porosity present in the various layers and the silver electrode with high resolution in 3D. The Landfester particle layer is found to have an undesired morphology with negatively correlated top- and bottom interfaces, wide thickness distribution and only partial surface coverage causing electric short circuits through the layer. By top coating a polymer material onto the Landfester nanoparticles we eliminate the structural defects of the layer such as porosity and roughness, and achieve the increased performance larger than 1 V expected for a tandem cell. This study highlights that quantitative imaging of weakly scattering stacked layers of organic materials has become feasible by PXCT, and that this information cannot be obtained by other methods. In the present study, this technique specifically reveals the need to improve the coatability and layer formation of Landfester nanoparticles, thus allowing improved solar cells to be produced. PMID:26220159

  20. Molding process for imidazopyrrolone polymers

    NASA Technical Reports Server (NTRS)

    Johnson, C. L. (Inventor)

    1973-01-01

    A process is described for producing shaped articles of imidazopyrrolone polymers comprising molding imidazopyrrolone polymer molding power under pressure and at a temperature greater than 475 C. Moderate pressures may be employed. Preferably, prior to molding, a preform is prepared by isostatic compression. The preform may be molded at a relatively low initial pressure and temperature; as the temperature is increased to a value greater than 475 C., the pressure is also increased.

  1. Large-scale ordering of nanoparticles using viscoelastic shear processing.

    PubMed

    Zhao, Qibin; Finlayson, Chris E; Snoswell, David R E; Haines, Andrew; Schäfer, Christian; Spahn, Peter; Hellmann, Goetz P; Petukhov, Andrei V; Herrmann, Lars; Burdet, Pierre; Midgley, Paul A; Butler, Simon; Mackley, Malcolm; Guo, Qixin; Baumberg, Jeremy J

    2016-01-01

    Despite the availability of elaborate varieties of nanoparticles, their assembly into regular superstructures and photonic materials remains challenging. Here we show how flexible films of stacked polymer nanoparticles can be directly assembled in a roll-to-roll process using a bending-induced oscillatory shear technique. For sub-micron spherical nanoparticles, this gives elastomeric photonic crystals termed polymer opals showing extremely strong tunable structural colour. With oscillatory strain amplitudes of 300%, crystallization initiates at the wall and develops quickly across the bulk within only five oscillations. The resulting structure of random hexagonal close-packed layers is improved by shearing bidirectionally, alternating between two in-plane directions. Our theoretical framework indicates how the reduction in shear viscosity with increasing order of each layer accounts for these results, even when diffusion is totally absent. This general principle of shear ordering in viscoelastic media opens the way to manufacturable photonic materials, and forms a generic tool for ordering nanoparticles. PMID:27255808

  2. Large-scale ordering of nanoparticles using viscoelastic shear processing

    PubMed Central

    Zhao, Qibin; Finlayson, Chris E.; Snoswell, David R. E.; Haines, Andrew; Schäfer, Christian; Spahn, Peter; Hellmann, Goetz P.; Petukhov, Andrei V.; Herrmann, Lars; Burdet, Pierre; Midgley, Paul A.; Butler, Simon; Mackley, Malcolm; Guo, Qixin; Baumberg, Jeremy J.

    2016-01-01

    Despite the availability of elaborate varieties of nanoparticles, their assembly into regular superstructures and photonic materials remains challenging. Here we show how flexible films of stacked polymer nanoparticles can be directly assembled in a roll-to-roll process using a bending-induced oscillatory shear technique. For sub-micron spherical nanoparticles, this gives elastomeric photonic crystals termed polymer opals showing extremely strong tunable structural colour. With oscillatory strain amplitudes of 300%, crystallization initiates at the wall and develops quickly across the bulk within only five oscillations. The resulting structure of random hexagonal close-packed layers is improved by shearing bidirectionally, alternating between two in-plane directions. Our theoretical framework indicates how the reduction in shear viscosity with increasing order of each layer accounts for these results, even when diffusion is totally absent. This general principle of shear ordering in viscoelastic media opens the way to manufacturable photonic materials, and forms a generic tool for ordering nanoparticles. PMID:27255808

  3. Large-scale ordering of nanoparticles using viscoelastic shear processing

    NASA Astrophysics Data System (ADS)

    Zhao, Qibin; Finlayson, Chris E.; Snoswell, David R. E.; Haines, Andrew; Schäfer, Christian; Spahn, Peter; Hellmann, Goetz P.; Petukhov, Andrei V.; Herrmann, Lars; Burdet, Pierre; Midgley, Paul A.; Butler, Simon; Mackley, Malcolm; Guo, Qixin; Baumberg, Jeremy J.

    2016-06-01

    Despite the availability of elaborate varieties of nanoparticles, their assembly into regular superstructures and photonic materials remains challenging. Here we show how flexible films of stacked polymer nanoparticles can be directly assembled in a roll-to-roll process using a bending-induced oscillatory shear technique. For sub-micron spherical nanoparticles, this gives elastomeric photonic crystals termed polymer opals showing extremely strong tunable structural colour. With oscillatory strain amplitudes of 300%, crystallization initiates at the wall and develops quickly across the bulk within only five oscillations. The resulting structure of random hexagonal close-packed layers is improved by shearing bidirectionally, alternating between two in-plane directions. Our theoretical framework indicates how the reduction in shear viscosity with increasing order of each layer accounts for these results, even when diffusion is totally absent. This general principle of shear ordering in viscoelastic media opens the way to manufacturable photonic materials, and forms a generic tool for ordering nanoparticles.

  4. Advanced Polymer Processing Facility

    SciTech Connect

    Muenchausen, Ross E.

    2012-07-25

    Some conclusions of this presentation are: (1) Radiation-assisted nanotechnology applications will continue to grow; (2) The APPF will provide a unique focus for radiolytic processing of nanomaterials in support of DOE-DP, other DOE and advanced manufacturing initiatives; (3) {gamma}, X-ray, e-beam and ion beam processing will increasingly be applied for 'green' manufacturing of nanomaterials and nanocomposites; and (4) Biomedical science and engineering may ultimately be the biggest application area for radiation-assisted nanotechnology development.

  5. Polymer-assisted metal deposition (PAMD): a full-solution strategy for flexible, stretchable, compressible, and wearable metal conductors.

    PubMed

    Yu, You; Yan, Casey; Zheng, Zijian

    2014-08-20

    Metal interconnects, contacts, and electrodes are indispensable elements for most applications of flexible, stretchable, and wearable electronics. Current fabrication methods for these metal conductors are mainly based on conventional microfabrication procedures that have been migrated from Si semiconductor industries, which face significant challenges for organic-based compliant substrates. This Research News highlights a recently developed full-solution processing strategy, polymer-assisted metal deposition (PAMD), which is particularly suitable for the roll-to-roll, low-cost fabrication of high-performance compliant metal conductors (Cu, Ni, Ag, and Au) on a wide variety of organic substrates including plastics, elastomers, papers, and textiles. This paper presents i) the principles of PAMD, and how to use it for making ii) flexible, stretchable, and wearable conductive metal electrodes, iii) patterned metal interconnects, and d) 3D stretchable and compressible metal sponges. A critical perspective on this emerging strategy is also provided. PMID:24458846

  6. Laser-induced porous graphene films from commercial polymers

    PubMed Central

    Lin, Jian; Peng, Zhiwei; Liu, Yuanyue; Ruiz-Zepeda, Francisco; Ye, Ruquan; Samuel, Errol L. G.; Yacaman, Miguel Jose; Yakobson, Boris I.; Tour, James M.

    2014-01-01

    Synthesis and patterning of carbon nanomaterials cost effectively is a challenge in electronic and energy storage devices. Here report a one-step, scalable approach for producing and patterning porous graphene films with 3-dimensional networks from commercial polymer films using a CO2 infrared laser. The sp3-carbon atoms are photothermally converted to sp2-carbon atoms by pulsed laser irradiation. The resulting laser-induced graphene (LIG) exhibits high electrical conductivity. The LIG can be readily patterned to interdigitated electrodes for in-plane microsupercapacitors with specific capacitances of >4 mF·cm−2 and power densities of ~9 mW·cm−2. Theoretical calculations partially suggest that enhanced capacitance may result from LIG’s unusual ultra-polycrystalline lattice of pentagon-heptagon structures. Combined with the advantage of one-step processing of LIG in air from commercial polymer sheets, which would allow the employment of a roll-to-roll manufacturing process, this technique provides a rapid route to polymer-written electronic and energy storage devices. PMID:25493446

  7. Laser-induced porous graphene films from commercial polymers.

    PubMed

    Lin, Jian; Peng, Zhiwei; Liu, Yuanyue; Ruiz-Zepeda, Francisco; Ye, Ruquan; Samuel, Errol L G; Yacaman, Miguel Jose; Yakobson, Boris I; Tour, James M

    2014-01-01

    The cost effective synthesis and patterning of carbon nanomaterials is a challenge in electronic and energy storage devices. Here we report a one-step, scalable approach for producing and patterning porous graphene films with three-dimensional networks from commercial polymer films using a CO2 infrared laser. The sp(3)-carbon atoms are photothermally converted to sp(2)-carbon atoms by pulsed laser irradiation. The resulting laser-induced graphene (LIG) exhibits high electrical conductivity. The LIG can be readily patterned to interdigitated electrodes for in-plane microsupercapacitors with specific capacitances of >4 mF cm(-2) and power densities of ~9 mW cm(-2). Theoretical calculations partially suggest that enhanced capacitance may result from LIG's unusual ultra-polycrystalline lattice of pentagon-heptagon structures. Combined with the advantage of one-step processing of LIG in air from commercial polymer sheets, which would allow the employment of a roll-to-roll manufacturing process, this technique provides a rapid route to polymer-written electronic and energy storage devices. PMID:25493446

  8. A high-order external distributed feedback polymer laser with low working threshold

    NASA Astrophysics Data System (ADS)

    Huang, Wenbin; Pu, Donglin; Yang, Xiaofei; Wei, Guojun; Fang, Zongbao; Zhou, Xiaohong; Qiao, Wen; Chen, Linsen

    2016-05-01

    In this paper, we report a high-order distributed feedback (DFB) polymer laser with low working threshold. Using the high-order grating increases the lithographic tolerances, providing coherent light sources that are more amenable to mass-manufacturing techniques, such as laser direct writing lithography and roll-to-roll processing. To enable high-order DFB lasing, an unconventional working configuration is designed in which the grating is situated on top of the uniform conjugated polymer film. In addition, a novel Forster energy transfer blend of two conjugated polymers is used as the gain medium. Upon pumping, the device emits lasing around 603.6 nm with a bandwidth of 0.5 nm. The threshold is around 20.5 μJ cm‑2 (~2.56 kW cm‑2), about to enter the regime of inexpensive LED pumping. A further increase in pump energy results in simultaneous oscillations at the 29th and 30th Bragg orders. Operating principles of the high-order DFB polymer laser, including spectral performance and threshold dependence on pump length, are investigated. This approach represents a step towards low-cost, even ‘disposable’ polymer lasers.

  9. Effect of molecular weight on polymer processability

    SciTech Connect

    Karg, R.F.

    1983-01-01

    Differences in rheological behavior due to the polymer molecular weight and molecular weight distribution have been shown with the MPT. SBR polymers having high molecular weight fractions develop higher stress relaxation time values due to the higher degree of polymer entanglements. Tests conducted at increasing temperatures show the diminishing influence of the polymer entanglements upon stress relaxation time. EPDM polymers show stress relaxation time and head pressure behavior which correlates with mill processability. As anticipated, compounded stock of EPDM have broad molecular weight distribution has higher stress relaxation time values than EPDM compounds with narrow molecular weight distribution.

  10. Processing of polymer surfaces by laser radiation

    NASA Astrophysics Data System (ADS)

    Kreutz, E. W.; Frerichs, H.; Stricker, J.; Wesner, D. A.

    1995-11-01

    The processing of polymer surfaces by laser radiation is investigated as a function of laser parameters (fluence, mode of operation) and processing variables (repetition rate, pulse number). Polymers under investigation are polyamide, polymethylmethacrylate, polypropylene, polystyrene, polycarbonate, acrylonitrile-butadiene-styrene copolymer, styrene-acrylonitrile copolymer, polybutadiene terephtalate, and polyoxymethylene, which are studied in air within different processing regimes such as modification of surface properties for subsequent metallization and removal of material for structuring of surface geometry. The metallization of polymers, which are pretreated by laser irradiation, wet chemical etching or plasma etching, is performed via electroplating and physical vapour deposition as a function of surface properties. The removal of polymers including non-thermal and thermal processes is done by direct processing techniques in the demagnification mode within one processing step. The diagnosis and the modelling of physical processes involved in tailoring the surface properties of polymers with laser radiation have to be implied to improve any application of these materials.

  11. Two timescales in polymer solidification: processing vs polymer crystallization

    NASA Astrophysics Data System (ADS)

    Piccarolo, Stefano; Poulose, Anesh M.; Carbone, Domenico

    2010-06-01

    In this work we compare the influence of a plasticizer on the density drop, and therefore on the disappearance of any long range order crystalline phases, observed after fast controlled quenching of PET and PBT. The plasticizer enhances significantly the maximum cooling rate at which PET still shows long range order crystalline phases while barely modifies the situation for PBT. The results are discussed on the basis of an interpretation of polymer crystallization strongly determined by the topology of the polymer, a view unconventional with respect to most of the well established interpretations of polymer crystallization all based on data obtained in a time scale much longer with respect to solidification in processing.

  12. Process for preparing polymer reinforced silica aerogels

    NASA Technical Reports Server (NTRS)

    Meador, Mary Ann B. (Inventor); Capadona, Lynn A. (Inventor)

    2011-01-01

    Process for preparing polymer-reinforced silica aerogels which comprises a one-pot reaction of at least one alkoxy silane in the presence of effective amounts of a polymer precursor to obtain a silica reaction product, the reaction product is gelled and subsequently subjected to conditions that promotes polymerization of the precursor and then supercritically dried to obtain the polymer-reinforced monolithic silica aerogels.

  13. CRADA final report: Technical assessment of roll-to-roll operation of lamination process, thermal treatment, and alternative carbon fiber precursors for low-cost, high-efficiency manufacturing of flow battery stacks and other energy devices

    SciTech Connect

    Daniel, Claus; Madden, Thomas; Wood, III, David L; Muth, Thomas R.; Warrington, Curtis; Ozcan, Soydan; Manson, Hunter; Tekinalp, Halil L.; Smith, Mark A.; Lu, Yuan; Loretz, Jeremy

    2015-09-23

    Among the various stationary-storage technologies under development, redox flow batteries (RFBs) offer the greatest potential to deliver inexpensive, scalable, and efficient grid-scale electrical-energy storage. Unlike traditional sealed batteries, in a flow battery power and energy are decoupled. Cell area and cell count in the stack determine the device power, and the chemical storage volume determines the total energy. Grid-scale energy-storage applications require megawatt-scale devices, which require the assembly of hundreds of large-area, bipolar cells per power plant. The cell-stack is the single system component with the largest impact on capital cost (due to the large number of highly engineered components) and operating costs (determined by overall round-trip efficiency).

  14. Improving organic tandem solar cells based on water-processed nanoparticles by quantitative 3D nanoimaging

    NASA Astrophysics Data System (ADS)

    Pedersen, E. B. L.; Angmo, D.; Dam, H. F.; Thydén, K. T. S.; Andersen, T. R.; Skjønsfjell, E. T. B.; Krebs, F. C.; Holler, M.; Diaz, A.; Guizar-Sicairos, M.; Breiby, D. W.; Andreasen, J. W.

    2015-08-01

    Organic solar cells have great potential for upscaling due to roll-to-roll processing and a low energy payback time, making them an attractive sustainable energy source for the future. Active layers coated with water-dispersible Landfester particles enable greater control of the layer formation and easier access to the printing industry, which has reduced the use of organic solvents since the 1980s. Through ptychographic X-ray computed tomography (PXCT), we image quantitatively a roll-to-roll coated photovoltaic tandem stack consisting of one bulk heterojunction active layer and one Landfester particle active layer. We extract the layered morphology with structural and density information including the porosity present in the various layers and the silver electrode with high resolution in 3D. The Landfester particle layer is found to have an undesired morphology with negatively correlated top- and bottom interfaces, wide thickness distribution and only partial surface coverage causing electric short circuits through the layer. By top coating a polymer material onto the Landfester nanoparticles we eliminate the structural defects of the layer such as porosity and roughness, and achieve the increased performance larger than 1 V expected for a tandem cell. This study highlights that quantitative imaging of weakly scattering stacked layers of organic materials has become feasible by PXCT, and that this information cannot be obtained by other methods. In the present study, this technique specifically reveals the need to improve the coatability and layer formation of Landfester nanoparticles, thus allowing improved solar cells to be produced.Organic solar cells have great potential for upscaling due to roll-to-roll processing and a low energy payback time, making them an attractive sustainable energy source for the future. Active layers coated with water-dispersible Landfester particles enable greater control of the layer formation and easier access to the printing

  15. Molecular Processing of Polymers with Cyclodextrins

    NASA Astrophysics Data System (ADS)

    Tonelli, Alan E.

    We summarize our recent studies employing the cyclic starch derivatives called cyclodextrins (CDs) to both nanostructure and functionalize polymers. Two important structural characteristics of CDs are taken advantage of to achieve these goals. First the ability of CDs to form noncovalent inclusion complexes (ICs) with a variety of guest molecules, including many polymers, by threading and inclusion into their relatively hydrophobic interior cavities, which are roughly cylindrical with diameters of ˜ 0.5 - 1.0 nm. α-, β-, and γ-CD contain six, seven, and eight α-1,4-linked glucose units, respectively. Warm water washing of polymer-CD-ICs containing polymer guests insoluble in water or treatment with amylase enzymes serves to remove the host CDs and results in the coalescence of the guest polymers into solid samples. When guest polymers are coalesced from the CD-ICs by removing their host CDs, they are observed to solidify with structures, morphologies, and even conformations that are distinct from bulk samples made from their solutions and melts. Molecularly mixed, intimate blends of two or more polymers that are normally immiscible can be obtained from their common CD-ICs, and the phase segregation of incompatible blocks can be controlled (suppressed or increased) in CD-IC coalesced block copolymers. In addition, additives may be more effectively delivered to polymers in the form of their crystalline CD-ICs or soluble CD-rotaxanes. Secondly, the many hydroxyl groups attached to the exterior rims of CDs, in addition to conferring water solubility, provide an opportunity to covalently bond them to polymers either during their syntheses or via postpolymerization reactions. Polymers containing CDs in their backbones or attached to their side chains are observed to more readily accept and retain additives, such as dyes and fragrances. Processing with CDs can serve to both nanostructure and functionalize polymers, leading to greater understanding of their behaviors

  16. Oil recovery process using polymer microemulsion complexes

    SciTech Connect

    Baker, E.G.; Canter, N.H.; Robbins, M.L.

    1982-11-23

    A process for the enhanced recovery of oil from a subterranean formation using a polymer-microemulsion complex is disclosed. The polymer is polyethylene oxide or polyvinyl pyrrolidone which interacts with the surfactant of the microemulsion to form a physical association. The resulting complex is characterized by a complexation energy of at least 2 kcal/mole. Slugs containing the present polymer-microemulsion complexes are stable at high salinity, show reduced destabilization due to surfactant adsorption and retention by the formation, have low interfacial tensions and achieve an early banking, as well as increased displacement of crude oil.

  17. Inkjet-based deposition of polymer thin films enabled by a lubrication model incorporating nano-scale parasitics

    NASA Astrophysics Data System (ADS)

    Singhal, Shrawan; Meissl, Mario J.; Bonnecaze, Roger T.; Sreenivasan, S. V.

    2013-09-01

    Thin film lubrication theory has been widely used to model multi-scale fluid phenomena. Variations of the same have also found application in fluid-based manufacturing process steps for micro- and nano-scale devices over large areas where a natural disparity in length scales exists. Here, a novel inkjet material deposition approach has been enabled by an enhanced thin film lubrication theory that accounts for nano-scale substrate parasitics. This approach includes fluid interactions with a thin flexible superstrate towards a new process called Jet and Coat of Thin-films (JCT). Numerical solutions of the model have been verified, and also validated against controlled experiments of polymer film deposition with good agreement. Understanding gleaned from the experimentally validated model has then been used to facilitate JCT process synthesis resulting in substantial reduction in the influence of parasitics and a concomitant improvement in the film thickness uniformity. Polymer films ranging from 20 to 500 nm mean thickness have been demonstrated with standard deviation of less than 2% of the mean film thickness. The JCT process offers advantages over spin coating which is not compatible with roll-to-roll processing and large area processing for displays. It also improves over techniques such as knife edge coating, slot die coating, as they are limited in the range of thicknesses of films that can be deposited without compromising uniformity.

  18. Polymers for nuclear materials processing

    SciTech Connect

    Jarvinen, G.; Benicewicz, B.; Duke, J.

    1996-10-01

    This is the final report of a one-year, Laboratory-Directed Research and Development (LDRD) project at the Los Alamos National Laboratory (LANL). The use of open-celled microcellular foams as solid sorbents for metal ions and other solutes could provide a revolutionary development in separation science. Macroreticular and gel-bead materials are the current state-of-the-art for solid sorbents to separate metal ions and other solutes from solution. The new polymer materials examined in this effort offer a number of advantages over the older materials that can have a large impact on industrial separations. The advantages include larger usable surface area in contact with the solution, faster sorption kinetics, ability to tailor the uniform cell size to a specific application, and elimination of channeling and packing instability.

  19. A novel polymer extrusion micropelletization process

    NASA Astrophysics Data System (ADS)

    Aquite, William

    Polymer micropellets provide a variety of potential applications for different processes in the polymer industry. Conventional pellets are in the size range of 2.5 mm to 5 mm, while micropellets are at least ten times smaller, in the size range of 50 μm to 1000 μm. The potential benefits to a processor using micropellets include: high surface to volume ratio, high bulk density, fast and even melting rates in extrusion, improved dry flow properties, faster injection molding cycles, and consequently lower energy consumption during processing. More specialized sintering processes that require polymer powders, such as selective sintering techniques, microporous plastics parts manufacturing, and other powder sintering methods would benefit from the production of polymer micropellets since these exhibit the advantages of pellets yet have a lower average size. This work focuses on the study of a technique developed at the Polymer Engineering Center. The technique uses a microcapillary die for the production of micropellets by causing instabilities in extruded polymer threads deformed using an air stream. Tuning of process conditions allow the development of surface disturbances that promote breakup of the threads into pellets, which are subsequently cooled and collected. Although micropellets with high sphericity and a narrow size distribution can be produced using this technique, minimal changes in process conditions also lead to the production of lenticular pellets as well as pellets, fibers and threads with a wide range of size and shape distributions. This work shows how changing processing conditions achieve a variety of shapes and sizes of micropellets, broadening its application for the production of powders from a variety of polymer resins. Different approaches were used, including dimensional analysis and numerical simulation of the micropelletization process. This research reveals the influence of non-linear viscoelastic effects on the dispersion of a polymer

  20. Interfacial Engineering for Highly Efficient-Conjugated Polymer-Based Bulk Heterojunction Photovoltaic Devices

    SciTech Connect

    Alex Jen; David Ginger; Christine Luscombe; Hong Ma

    2012-04-02

    The aim of our proposal is to apply interface engineering approach to improve charge extraction, guide active layer morphology, improve materials compatibility, and ultimately allow the fabrication of high efficiency tandem cells. Specifically, we aim at developing: i. Interfacial engineering using small molecule self-assembled monolayers ii. Nanostructure engineering in OPVs using polymer brushes iii. Development of efficient light harvesting and high mobility materials for OPVs iv. Physical characterization of the nanostructured systems using electrostatic force microscopy, and conducting atomic force microscopy v. All-solution processed organic-based tandem cells using interfacial engineering to optimize the recombination layer currents vi. Theoretical modeling of charge transport in the active semiconducting layer The material development effort is guided by advanced computer modeling and surface/ interface engineering tools to allow us to obtain better understanding of the effect of electrode modifications on OPV performance for the investigation of more elaborate device structures. The materials and devices developed within this program represent a major conceptual advancement using an integrated approach combining rational molecular design, material, interface, process, and device engineering to achieve solar cells with high efficiency, stability, and the potential to be used for large-area roll-to-roll printing. This may create significant impact in lowering manufacturing cost of polymer solar cells for promoting clean renewable energy use and preventing the side effects from using fossil fuels to impact environment.

  1. Polymer micromold and fabrication process

    SciTech Connect

    Lee, A.P.; Northrup, M.A.; Ahre, P.E.; Dupuy, P.C.

    1997-08-19

    A mold assembly is disclosed with micro-sized features in which the hollow portion thereof is fabricated from a sacrificial mandrel which is surface treated and then coated to form an outer shell. The sacrificial mandrel is then selectively etched away leaving the outer shell as the final product. The sacrificial mandrel is fabricated by a precision lathe, for example, so that when removed by etching the inner or hollow area has diameters as small as 10`s of micros ({micro}m). Varying the inside diameter contours of the mold can be accomplished with specified ramping slopes formed on the outer surface of the sacrificial mandrel, with the inside or hollow section being, for example, 275 {micro}m in length up to 150 {micro}m in diameter within a 6 mm outside diameter (o.d.) mold assembly. The mold assembly itself can serve as a micronozzle or microneedle, and plastic parts, such as microballoons for angioplasty, polymer microparts, and microactuators, etc., may be formed within the mold assembly. 6 figs.

  2. Polymer micromold and fabrication process

    SciTech Connect

    Lee, Abraham P.; Northrup, M. Allen; Ahre, Paul E.; Dupuy, Peter C.

    1997-01-01

    A mold assembly with micro-sized features in which the hollow portion thereof is fabricated from a sacrificial mandrel which is surface treated and then coated to form an outer shell. The sacrificial mandrel is then selectively etched away leaving the outer shell as the final product. The sacrificial mandrel is fabricated by a precision lathe, for example, so that when removed by etching the inner or hollow area has diameters as small as 10's of micros (.mu.m). Varying the inside diameter contours of the mold can be accomplished with specified ramping slopes formed on the outer surface of the sacrificial mandrel, with the inside or hollow section being, for example, 275 .mu.m in length up to 150 .mu.m in diameter within a 6 mm outside diameter (o.d.) mold assembly. The mold assembly itself can serve as a micronozzle or microneedle, and plastic parts, such as microballoons for angioplasty, polymer microparts, and microactuators, etc., may be formed within the mold assembly.

  3. An Integrated Young Interferometer Based on UV-Imprinted Polymer Waveguides for Label-Free Biosensing Applications

    NASA Astrophysics Data System (ADS)

    Wang, M.; Hiltunen, J.; Liedert, C.; Hakalahti, L.; Myllylä, R.

    2012-06-01

    We demonstrate a polymer rib waveguide Young interferometer sensor fabricated by UV-imprinting. An inverted rib waveguide structure was utilized in order to simplify the fabrication process. In this configuration grooves are formed on the under cladding layer by UV-imprinting and core material is spin coated on top to fill the grooves. Glucose water solution was used to characterize the sensor response against ambient refractive index changes. The sensing responses correspond linearly with the refractive index change of glucose solutions with a detection limit of about 10-5. To verify the capability of the polymer sensor for biosensing, an immunoassay was performed with c-reactive protein (CRP) and human CRP specific antibody adsorbed on the waveguide surface as a receptor. The CRP solution in PBS (phosphate buffered saline) buffer with a concentration of 2 μg/ml (16 nM) resulted in an obvious response which was over a couple hundred times of the noise level. Based on these values, a detection limit of about 2.4 pg/mm^2 was found for the surface sensing of molecular adsorption. With the proposed waveguide configuration, the fabrication of polymer sensors can be ultimately transferred to roll-to-roll mass production to produce low-cost disposable sensors.

  4. Thermal Imaging Processes of Polymer Nanocomposite Coatings

    NASA Astrophysics Data System (ADS)

    Meth, Jeffrey

    2015-03-01

    Laser induced thermal imaging (LITI) is a process whereby infrared radiation impinging on a coating on a donor film transfers that coating to a receiving film to produce a pattern. This talk describes how LITI patterning can print color filters for liquid crystal displays, and details the physical processes that are responsible for transferring the nanocomposite coating in a coherent manner that does not degrade its optical properties. Unique features of this process involve heating rates of 107 K/s, and cooling rates of 104 K/s, which implies that not all of the relaxation modes of the polymer are accessed during the imaging process. On the microsecond time scale, the polymer flow is forced by devolatilization of solvents, followed by deformation akin to the constrained blister test, and then fracture caused by differential thermal expansion. The unique combination of disparate physical processes demonstrates the gamut of physics that contribute to advanced material processing in an industrial setting.

  5. Automatic Processing of Reactive Polymers

    NASA Technical Reports Server (NTRS)

    Roylance, D.

    1985-01-01

    A series of process modeling computer codes were examined. The codes use finite element techniques to determine the time-dependent process parameters operative during nonisothermal reactive flows such as can occur in reaction injection molding or composites fabrication. The use of these analytical codes to perform experimental control functions is examined; since the models can determine the state of all variables everywhere in the system, they can be used in a manner similar to currently available experimental probes. A small but well instrumented reaction vessel in which fiber-reinforced plaques are cured using computer control and data acquisition was used. The finite element codes were also extended to treat this particular process.

  6. Stochastic resonance during a polymer translocation process

    NASA Astrophysics Data System (ADS)

    Mondal, Debasish; Muthukumar, Murugappan

    We study the translocation of a flexible polymer in a confined geometry subjected to a time-periodic external drive to explore stochastic resonance. We describe the equilibrium translocation process in terms of a Fokker-Planck description and use a discrete two-state model to describe the effect of the external driving force on the translocation dynamics. We observe that no stochastic resonance is possible if the associated free-energy barrier is purely entropic in nature. The polymer chain experiences a stochastic resonance effect only in presence of an energy threshold in terms of polymer-pore interaction. Once stochastic resonance is feasible, the chain entropy controls the optimal synchronization conditions significantly.

  7. Progress in radiation processing of polymers

    NASA Astrophysics Data System (ADS)

    Chmielewski, Andrzej G.; Haji-Saeid, Mohammad; Ahmed, Shamshad

    2005-07-01

    Modification in polymeric structure of plastic material can be brought either by conventional chemical means or by exposure to ionization radiation from ether radioactive sources or highly accelerated electrons. The prominent drawbacks of chemical cross-linking typically involve the generation of noxious fumes and by products of peroxide degradation. Both the irradiation sources have their merits and limitations. Increased utilization of electron beams for modification and enhancement of polymer materials has been in particular witnessed over the past 40 years. The paper highlights several recent cases of EB utilization to improve key properties of selected plastic products. In paper is provided a survey of radiation processing methods of industrial interest, encompassing technologies which are already commercially well established, through developments in the active R&D stage which show pronounced promise for future commercial use. Radiation cross-linking technologies discussed include: application in cable and wire, application in rubber tyres, radiation vulcanization of rubber latex, development of radiation crosslinked SiC fiber, polymer recycling, development of gamma compatible pp, hydrogels etc. Over the years, remarkable advancement has been achieved in radiation processing of natural polymers. Role of radiation in improving the processing of temperature of PCL for use as biodegradable polymer, in accelerated breakdown of cellulose into viscose and enhancement in yields of chitin/chitosan from sea-food waste, is described.

  8. Materials Science and Technology, Volume 18, Processing of Polymers

    NASA Astrophysics Data System (ADS)

    Meijer, Han E. H.

    1997-06-01

    Polymer processing has a profound effect on the final properties and thus the applications of plastics. Leading international scientists and engineers have contributed to this unique self- contained handbook making it indispensable to polymer scientists and engineers. Contents: Meijer: Processing for Properties. Agassant: General Principles of Polymer Processing Modeling. Janssen: Emulsions: The Dynamics of Liquid-Liquid Mixing. Keller/Kolnaar: Flow-Induced Orientation and Structure Formation. Janeschitz-Kriegl/Eder: Crystallization. Hu/Lambla: Fundamentals of Reactive Extrusion. Dusek: Network Formation. Maréchal/Inoue: Reactive Processing of Polymer Blends: Polymer-Polymer Interface Aspects. Stanford/Ryan/Elwell: Structure Development in Reactive Systems. Lemstra/Meijer: Processing of Polymers Using Reactive Solvents. Bastiaansen: High-Modulus and High-Strength Fibers Based on Flexible Macromolecules. van der Sanden: Deformation and Toughness of Polymers. Decker: Photopolymerization and UV-Curing of Multifunctional Monomers. Wilson: Conducting Polymers and Applications. Creton: Materials Science of Pressure-Sensitive Adhesives. Ward: New Processing Technologies.

  9. Investigation of the interfacial adhesion of the transparent conductive oxide films to large-area flexible polymer substrates using laser-induced thermo-mechanical stresses

    NASA Astrophysics Data System (ADS)

    Park, Jin-Woo; Lee, Seung-Ho; Yang, Chan-Woo

    2013-08-01

    In this study, we investigated the interfacial adhesion strength (σint) of transparent conductive oxide (TCO) coatings on polymer substrates using a nanosecond Nd:YAG pulsed laser. We compared our results with those achieved using conventional testing methods such as bending and fragmentation tests as well as theoretical calculations. In the fragmentation and bending tests, mechanical compressive stress is induced in the film due to mismatches in Poisson's ratio and Young's modulus between the substrate and film. But, the incident laser makes the film under compression due to the mismatch in thermal expansion between the TCO and the polymer substrate. With a pulse incident to the substrate, the TCO rapidly expands by laser-induced instant heating while the transparent polymer does little, which causes the TCO to buckle and delaminate over the critical pulse energy. The critical compressive stress that scales with σint was calculated using simple equations, which agreed well with the results from previous theoretical calculations. Because the films preferentially delaminate at the defects and grain boundaries, this technique also provided useful information regarding the interface microstructures. Moreover, because the laser can scan over large areas, this method is suitable for flexible substrates that are produced by a roll-to-roll process. Nevertheless, the mechanical stress introduced by the bending and fragmentation tests causes the TCO to buckle without interfacial delamination. Hence, the stresses at the buckling disagreed with the results obtained from the laser test and the theoretical calculations.

  10. Efficient organic solar cells processed from hydrocarbon solvents

    NASA Astrophysics Data System (ADS)

    Zhao, Jingbo; Li, Yunke; Yang, Guofang; Jiang, Kui; Lin, Haoran; Ade, Harald; Ma, Wei; Yan, He

    2016-02-01

    Organic solar cells have desirable properties, including low cost of materials, high-throughput roll-to-roll production, mechanical flexibility and light weight. However, all top-performance devices are at present processed using halogenated solvents, which are environmentally hazardous and would thus require expensive mitigation to contain the hazards. Attempts to process organic solar cells from non-halogenated solvents lead to inferior performance. Overcoming this hurdle, here we present a hydrocarbon-based processing system that is not only more environmentally friendly but also yields cells with power conversion efficiencies of up to 11.7%. Our processing system incorporates the synergistic effects of a hydrocarbon solvent, a novel additive, a suitable choice of polymer side chain, and strong temperature-dependent aggregation of the donor polymer. Our results not only demonstrate a method of producing active layers of organic solar cells in an environmentally friendly way, but also provide important scientific insights that will facilitate further improvement of the morphology and performance of organic solar cells.

  11. Grid-connected polymer solar panels: initial considerations of cost, lifetime, and practicality.

    PubMed

    Medford, Andrew J; Lilliedal, Mathilde R; Jørgensen, Mikkel; Aarø, Dennis; Pakalski, Heinz; Fyenbo, Jan; Krebs, Frederik C

    2010-09-13

    Large solar panels were constructed from polymer solar cell modules prepared using full roll-to-roll (R2R) manufacture based on the previously published ProcessOne. The individual flexible polymer solar modules comprising multiple serially connected single cell stripes were joined electrically and laminated between a 4 mm tempered glass window and black Tetlar foil using two sheets of 0.5 mm thick ethylene vinyl acetate (EVA). The panels produced up to 8 W with solar irradiance of ~960 Wm⁻², and had outer dimensions of 1 m x 1.7 m with active areas up to 9180 cm². Panels were mounted on a tracking station and their output was grid connected between testing. Several generations of polymer solar cells and panel constructions were tested in this context to optimize the production of polymer solar panels. Cells lacking a R2R barrier layer were found to degrade due to diffusion of oxygen after less than a month, while R2R encapsulated cells showed around 50% degradation after 6 months but suffered from poor performance due to de-lamination during panel production. A third generation of panels with various barrier layers was produced to optimize the choice of barrier foil and it was found that the inclusion of a thin protective foil between the cell and the barrier foil is critical. The findings provide a preliminary foundation for the production and optimization of large-area polymer solar panels and also enabled a cost analysis of solar panels based on polymer solar cells. PMID:21165057

  12. FEL for the polymer processing industries

    NASA Astrophysics Data System (ADS)

    Kelley, Michael J.

    1997-05-01

    Polymers are everywhere in modern life because of their unique combination of end-use functionalities, ease of processing, recycling potential and modest cost. The physical and economic scope of the infrastructure committed to present polymers makes the introduction of entirely new chemistry unlikely. Rather, the breadth of commercial offerings more likely to shrink in the face of the widening mandate for recycling, especially of packaging. Improved performance and new functionality must therefore come by routes such as surface modification. However they must come with little environmental impact and at painfully low cost. Processing with strongly absorbed light offers unique advantages. The journal and patent literatures disclose a number of examples of benefits that can be achieved, principally by use of excimer lasers or special UV lamps. Examples of commercialization are few, however, because of the unit cost and maximum scale of existing light sources. A FEL, however, offers unique advantages: tunability to the optimum wavelength, potential for scale up to high average power, and a path to attractively low unit cost of light. A business analysis of prospective applications defines the technical and economic requirements a FEL for polymer surface processing must meet. These are compared to FEL technology as it now stands and as it is envisioned.

  13. Asymmetric Mach-Zehnder interferometers without an interaction window in polymer foils for refractive index sensing.

    PubMed

    Hofmann, Meike; Xiao, Yanfen; Sherman, Stanislav; Gleissner, Uwe; Schmidt, Thomas; Zappe, Hans

    2016-02-10

    We report on the fabrication and characterization of integrated Mach-Zehnder interferometers in polymer foil without an interaction window. The interferometers are based on inverted rib waveguides, which allow single mode behavior even for waveguide widths larger than a few micrometers. The phase change between the two interferometer arms upon a refractive index change of the analyte that serves as the upper cladding is generated by the asymmetricity of the two interferometer arms. A difference of the waveguide width in the straight part of the interferometer leads to different effective refractive indices and thus to a change in the interference signal. We show in small scale the process chain, which is compatible with a cost-effective roll-to-roll fabrication process. For a proof of principle we apply deionized water and a glucose solution as analytes to the sensor foils and detect the transmitted intensity as a measure of the induced phase change. A detection limit of 3·10⁻³ refractive index units is reached for homogeneous sensing at a total system length of 9.3 mm and a total waveguide core thickness of 3 μm. PMID:26906387

  14. Utilizing insulating nanoparticles as the spacer in laminated flexible polymer solar cells for improved mechanical stability.

    PubMed

    Lu, Yunzhang; Alexander, Clement; Xiao, Zhengguo; Yuan, Yongbo; Zhang, Runyu; Huang, Jinsong

    2012-08-31

    Roll-to-roll lamination is one promising technique to produce large-area organic electronic devices such as solar cells with a large through output. One challenge in this process is the frequent electric point shorting of the cathode and anode by the excess or concentrated applied stress from many possible sources. In this paper, we report a method to avoid electric point shorting by incorporating insulating and hard barium titanate (BaTiO(3)) nanoparticles (NPs) into the active layer to work as a spacer. It has been demonstrated that the incorporated BaTiO(3) NPs in poly(3-hexylthiophene):[6,6]-phenyl-c-61-butyric acid methyl ester (P3HT:PCBM) bulk heterojunction solar cells cause no deleterious effect to the power conversion process of this type of solar cell. The resulting laminated devices with NPs in the active layer display the same efficiency as the devices without NPs, while the laminated devices with NPs can sustain a ten times higher lamination stress of over 6 MPa. The flexible polymer solar cell device with incorporated NPs shows a much smaller survivable curvature radius of 4 mm, while a regular flexible device can only sustain a bending curvature radius of 8 mm before fracture. PMID:22886059

  15. Magnetic field processing of inorganic polymers

    SciTech Connect

    Kunerth, D.C.; Peterson, E.S.

    1995-05-01

    The purpose of this project is to investigate, understand, and demonstrate the use of magnetic field processing (MFP) to modify the properties of inorganic-based polymers and to develop the basic technical knowledge required for industrial implementation. Polyphosphazene membranes for chemical separation applications are being emphasized by this project. Previous work demonstrated that magnetic fields, appropriately applied during processing, can be used to beneficially modify membrane morphology. MFP membranes have significantly increased flux capabilities while maintaining the same chemical selectivity as the unprocessed membranes.

  16. Reduced biodegradability in a polymer flood process

    SciTech Connect

    Williams, D.; Munnecke, D. M.

    1985-05-14

    In a polymer flood, where bacterial contamination frequently causes a loss in viscosity of the polymer, the viscosity of the polymer solution is maintained by the use of a xanthan polymer modified by methylation of a portion of the subunit sugar residues of the xanthan base.

  17. Bidirectional Control of Flow in Thin Polymer Films by Photochemically Manipulating Surface Tension

    NASA Astrophysics Data System (ADS)

    Kim, Chae Bin; Janes, Dustin; Zhou, Sunshine; Dulaney, Austin; Ellison, Christopher

    The Marangoni effect causes transport of liquids in response to surface tension gradients. In a thin polymer film, such flow results in formation of topographic features that could be exploited as a practically useful route to manufacture patterned surfaces. An especially versatile material for this application should be able to be spatially programmed to possess regions of higher or lower relative surface tension so that the direction of flow into or out of those regions can be directed with precision. To this end, we describe here a photopolymer whose melt-state surface tension can be selectively raised or lowered in light exposed regions depending on the wavelength and dose of applied light. The direction of Marangoni flow into or out of irradiated regions agrees with expected surface tension changes associated with each photochemical transformation. We believe this patterning methodology will be potentially useful for high throughput fabrication environments such as roll-to-roll processing that can exploit contact-free and solvent-free topography development.

  18. An indium tin oxide-free polymer solar cell on flexible glass.

    PubMed

    Formica, Nadia; Mantilla-Perez, Paola; Ghosh, Dhriti S; Janner, Davide; Chen, Tong Lai; Huang, Minghuang; Garner, Sean; Martorell, Jordi; Pruneri, Valerio

    2015-03-01

    Future optoelectronic devices and their low-cost roll-to-roll production require mechanically flexible transparent electrodes (TEs) and substrate materials. Indium tin oxide (ITO) is the most widely used TE because of its high optical transmission and low electrical sheet resistance. However, ITO, besides being expensive, has very poor performance under mechanical stress because of its fragile oxide nature. Alternative TE materials have thus been sought. Here we report the development of a multilayer TiO2/Ag/Al-doped ZnO TE structure and an ITO-free polymer solar cell (PSC) incorporating it. Electro-optical performances close to those of ITO can be achieved for the proposed TE and corresponding PSC with an additional advantage in their mechanical flexibility, as demonstrated by the fact that the cell efficiency maintains 94% of its initial value (6.6%) after 400 cycles of bending, with 6 and 3 cm maximum and minimum radii, respectively. Instead of common plastic materials, our work uses a very thin (0.14 mm) flexible glass substrate with several benefits, such as the possibility of high-temperature processes, superior antipermeation properties against oxygen and moisture, and improved film adhesion. PMID:25654433

  19. Stability Comparison of Perovskite Solar Cells Based on Zinc Oxide and Titania on Polymer Substrates.

    PubMed

    Dkhissi, Yasmina; Meyer, Steffen; Chen, Dehong; Weerasinghe, Hasitha C; Spiccia, Leone; Cheng, Yi-Bing; Caruso, Rachel A

    2016-04-01

    Device scale-up and long-term stability constitute two major hurdles that the emerging perovskite solar technology will have to overcome before commercialization. Here, a comparative study was performed between ZnO and TiO2 electron-selective layers, two materials that allow the low-temperature processing of perovskite solar cells on polymer substrates. Although the use of TiO2 is well established on glass substrates, ZnO was chosen because it can be readily printed at low temperature and offers the potential for the large-scale roll-to-roll manufacturing of flexible photovoltaics at a low cost. However, a rapid degradation of CH3 NH3 PbI3 was observed if it was deposited on ZnO, therefore, the influence of the perovskite film preparation conditions on its morphology and degradation kinetics was investigated. This study showed that CH3 NH3 PbI3 could withstand a higher temperature on TiO2 than ZnO and that TiO2 -based perovskite devices were more stable than their ZnO analogues. PMID:26893225

  20. Process for hardening the surface of polymers

    DOEpatents

    Mansur, L.K.; Lee, E.H.

    1992-07-14

    Hard surfaced polymers and the method for making them is generally described. Polymers are subjected to simultaneous multiple ion beam bombardment, that results in a hardening of the surface and improved wear resistance. 1 figure.

  1. Process for hardening the surface of polymers

    DOEpatents

    Mansur, Louis K.; Lee, Eal H.

    1992-01-01

    Hard surfaced polymers and the method for making them is generally described. Polymers are subjected to simultaneous multiple ion beam bombardment, that results in a hardening of the surface and improved wear resistance.

  2. Process to produce lithium-polymer batteries

    DOEpatents

    MacFadden, Kenneth Orville

    1998-01-01

    A polymer bonded sheet product suitable for use as an electrode in a non-aqueous battery system. A porous electrode sheet is impregnated with a solid polymer electrolyte, so as to diffuse into the pores of the electrode. The composite is allowed to cool, and the electrolyte is entrapped in the porous electrode. The sheet products composed have the solid polymer electrolyte composition diffused into the active electrode material by melt-application of the solid polymer electrolyte composition into the porous electrode material sheet. The solid polymer electrolyte is maintained at a temperature that allows for rapid diffusion into the pores of the electrode. The composite electrolyte-electrode sheets are formed on current collectors and can be coated with solid polymer electrolyte prior to battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte coating has low resistance.

  3. Process to produce lithium-polymer batteries

    DOEpatents

    MacFadden, K.O.

    1998-06-30

    A polymer bonded sheet product is described suitable for use as an electrode in a non-aqueous battery system. A porous electrode sheet is impregnated with a solid polymer electrolyte, so as to diffuse into the pores of the electrode. The composite is allowed to cool, and the electrolyte is entrapped in the porous electrode. The sheet products composed have the solid polymer electrolyte composition diffused into the active electrode material by melt-application of the solid polymer electrolyte composition into the porous electrode material sheet. The solid polymer electrolyte is maintained at a temperature that allows for rapid diffusion into the pores of the electrode. The composite electrolyte-electrode sheets are formed on current collectors and can be coated with solid polymer electrolyte prior to battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte coating has low resistance. 1 fig.

  4. Laser Processing of Metals and Polymers

    SciTech Connect

    Singaravelu, Senthilraja

    2012-05-01

    A laser offers a unique set of opportunities for precise delivery of high quality coherent energy. This energy can be tailored to alter the properties of material allowing a very flexible adjustment of the interaction that can lead to melting, vaporization, or just surface modification. Nowadays laser systems can be found in nearly all branches of research and industry for numerous applications. Sufficient evidence exists in the literature to suggest that further advancements in the field of laser material processing will rely significantly on the development of new process schemes. As a result they can be applied in various applications starting from fundamental research on systems, materials and processes performed on a scientific and technical basis for the industrial needs. The interaction of intense laser radiation with solid surfaces has extensively been studied for many years, in part, for development of possible applications. In this thesis, I present several applications of laser processing of metals and polymers including polishing niobium surface, producing a superconducting phase niobium nitride and depositing thin films of niobium nitride and organic material (cyclic olefin copolymer). The treated materials were examined by scanning electron microscopy (SEM), electron probe microanalysis (EPMA), atomic force microscopy (AFM), high resolution optical microscopy, surface profilometry, Fourier transform infrared spectroscopy (FTIR) and x-ray diffraction (XRD). Power spectral density (PSD) spectra computed from AFM data gives further insight into the effect of laser melting on the topography of the treated niobium.

  5. Fine tuning of the PCDTBT-OR:PC71BM blend nanoscale phase separation via selective solvent annealing toward high-performance polymer photovoltaics

    NASA Astrophysics Data System (ADS)

    Meng, Bin; Fang, Gang; Fu, Yingying; Xie, Zhiyuan; Wang, Lixiang

    2013-12-01

    Solution-processable polymer solar cells show great promise for providing a cost-effective route to create lightweight and flexible solar energy conversion devices. The photoactive layer comprising the conjugated polymer donor and fullerene derivative acceptor must be optimized to form bicontinuous nanoscale phase separation in order for efficient exciton dissociation and charge collection due to the short exciton diffusion length of organic semiconductors. The donor polymer poly[9-(heptadecan-9-yl)-9H-carbazole- 2,7-diyl-alt-(5,6-bis(hexyloxy)-4,7-di(thiophen-2- yl)benzo[c][1,2,5]thiadiazole)-5,5-diyl] (PCDTBT-OR) has a deeper highest occupied molecular orbital level compared to its counterpart PCDTBT, and shows promise in increasing the open-circuit voltage and power conversion efficiency (PCE) of polymer solar cells. The phase separation evolution of the PCDTBT-OR:PC71BM blend with various weight ratios under tetrahydrofuran (THF) vapor annealing and its influence on the photovoltaic performance is investigated in detail. It is found that THF vapor annealing can promote the acceptor PC71BM aggregation from the donor PCDTBT-OR matrix to form nanoscale donor/acceptor phase separation for efficient exciton dissociation and charge collection depending on the donor/acceptor weight ratio and the annealing time. The THF vapor-annealed PCDTBT-OR:PC71BM solar cells exhibit remarkable enhancement, with a PCE of 7.01% compared to 3.25% of the as-cast solar cells with the same active layer thickness. This work provides a general methodology to construct nano-interpenetrating networks for homogeneous polymer/fullerene blends and is potentially applicable to the roll-to-roll manufacturing of polymer solar cells.

  6. High transmittance optical films based on quantum dot doped nanoscale polymer dispersed liquid crystals

    NASA Astrophysics Data System (ADS)

    Gandhi, Sahil Sandesh; Chien, Liang-Chy

    2016-04-01

    We propose a simple way to fabricate highly transparent nanoscale polymer dispersed liquid crystal (nano-PDLC) films between glass substrates and investigate their incident angle dependent optical transmittance properties with both collimated and Lambertian intensity distribution light sources. We also demonstrate that doping nano-PDLC films with 0.1% InP/ZnS core/shell quantum dots (QD) results in a higher optical transmittance. This work lays the foundation for such nanostructured composites to potentially serve as roll-to-roll coatable light extraction or brightness enhancement films in emissive display applications, superior to complex nanocorrugation techniques proposed in the past.

  7. Experiments towards establishing of design rules for R2R-UV-NIL with polymer working shims

    NASA Astrophysics Data System (ADS)

    Nees, Dieter; Ruttloff, Stephan; Palfinger, Ursula; Stadlober, Barbara

    2016-03-01

    Roll-to-Roll-UV-nanoimprint lithography (R2R-UV-NIL) enables high resolution large area patterning of flexible substrates and is therefore of increasing industrial interest. We have set up a custom-made R2R-UV-NIL pilot machine which is able to convert 10 inch wide web with velocities of up to 30 m/min. In addition, we have developed self-replicable UV-curable resins with tunable surface energy and Young's modulus for UV-imprint material as well as for polymer working stamp/shim manufacturing. Now we have designed test patterns for the evaluation of the impact of structure shape, critical dimension, pitch, depth, side wall angle and orientation relative to the web movement onto the imprint fidelity and working shim life time. We have used female (recessed structures) silicon masters of that design with critical dimensions between CD = 200 nm and 1600 nm, and structure depths of d = 500 nm and 1000 nm - all with vertical as well as inclined side walls. These entire master patterns have been transferred onto single male (protruding structures) R2R polymer working shims. The polymer working shims have been used for R2R-UV-NIL runs of several hundred meters and the imprint fidelity and process stability of the various test patterns have been compared. This study is intended as a first step towards establishing of design rules and developing of nanoimprint proximity correction strategies for industrial R2R-UV-NIL processes using polymer working shims.

  8. Effect of processing on Polymer/Composite structure and properties

    NASA Technical Reports Server (NTRS)

    1982-01-01

    Advances in the vitality and economic health of the field of polymer forecasting are discussed. A consistent and rational point of view which considers processing as a participant in the underlying triad of relationships which comprise materials science and engineering is outlined. This triad includes processing as it influences material structure, and ultimately properties. Methods in processing structure properties, polymer science and engineering, polymer chemistry and synthesis, structure and modification and optimization through processing, and methods of melt flow modeling in processing structure property relations of polymer were developed. Mechanical properties of composites are considered, and biomedical materials research to include polymer processing effects are studied. An analysis of the design technology of advances graphite/epoxy composites is also reported.

  9. Stability analysis of a polymer coating process

    NASA Astrophysics Data System (ADS)

    Kallel, A.; Hachem, E.; Demay, Y.; Agassant, J. F.

    2015-05-01

    A new coating process involving a short stretching distance (1 mm) and a high draw ratio (around 200) is considered. The resulting thin molten polymer film (around 10 micrometers) is set down on a solid primary film and then covered by another solid secondary film. In experimental studies, periodical fluctuation in the thickness of the coated layer may be observed. The processing conditions markedly influence the onset and the development of these defects and modeling will help our understanding of their origins. The membrane approach which has been commonly used for cast film modeling is no longer valid and two dimensional time dependent models (within the thickness) are developed in the whole domain (upstream die and stretching path). A boundary-value problem with a free surface for the Stokes equations is considered and stability of the free surface is assessed using two different numerical strategies: a tracking strategy combined with linear stability analysis involving computation of leading eigenvalues, and a Level Set capturing strategy coupled with transient stability analysis.

  10. Process for crosslinking and extending conjugated diene-containing polymers

    NASA Technical Reports Server (NTRS)

    Bell, Vernon L. (Inventor); Havens, Stephen J. (Inventor)

    1977-01-01

    A process using a Diels-Alder reaction which increases the molecular weight and/or crosslinks polymers by reacting the polymers with bisunsaturated dienophiles is developed. The polymer comprises at least 75% by weight based on the reaction product, has a molecular weight of at least 5000 and a plurality of conjugated 1,3-diene systems incorporated into the molecular structure. A dienophile reaction with the conjugated 1,3-diene of the polymer is at least 1% by weight based on the reaction product. Examples of the polymer include polyesters, polyamides, polyethers, polysulfones and copolymers. The bisunsaturated dienophiles may include bis-maleimides, bis maleic and bis tumaric esters and amides. This method for expanding the molecular weight chains of the polymers, preferable thermoplastics, is advantageous for processing or fabricating thermoplastics. A low molecular weight thermoplastic is converted to a high molecular weight plastic having improved strength and toughness for use in the completed end use article.

  11. Stochastic resonance during a polymer translocation process.

    PubMed

    Mondal, Debasish; Muthukumar, M

    2016-04-14

    We have studied the occurrence of stochastic resonance when a flexible polymer chain undergoes a single-file translocation through a nano-pore separating two spherical cavities, under a time-periodic external driving force. The translocation of the chain is controlled by a free energy barrier determined by chain length, pore length, pore-polymer interaction, and confinement inside the donor and receiver cavities. The external driving force is characterized by a frequency and amplitude. By combining the Fokker-Planck formalism for polymer translocation and a two-state model for stochastic resonance, we have derived analytical formulas for criteria for emergence of stochastic resonance during polymer translocation. We show that no stochastic resonance is possible if the free energy barrier for polymer translocation is purely entropic in nature. The polymer chain exhibits stochastic resonance only in the presence of an energy threshold in terms of polymer-pore interactions. Once stochastic resonance is feasible, the chain entropy controls the optimal synchronization conditions significantly. PMID:27083746

  12. Stochastic resonance during a polymer translocation process

    NASA Astrophysics Data System (ADS)

    Mondal, Debasish; Muthukumar, M.

    2016-04-01

    We have studied the occurrence of stochastic resonance when a flexible polymer chain undergoes a single-file translocation through a nano-pore separating two spherical cavities, under a time-periodic external driving force. The translocation of the chain is controlled by a free energy barrier determined by chain length, pore length, pore-polymer interaction, and confinement inside the donor and receiver cavities. The external driving force is characterized by a frequency and amplitude. By combining the Fokker-Planck formalism for polymer translocation and a two-state model for stochastic resonance, we have derived analytical formulas for criteria for emergence of stochastic resonance during polymer translocation. We show that no stochastic resonance is possible if the free energy barrier for polymer translocation is purely entropic in nature. The polymer chain exhibits stochastic resonance only in the presence of an energy threshold in terms of polymer-pore interactions. Once stochastic resonance is feasible, the chain entropy controls the optimal synchronization conditions significantly.

  13. Thermal property and processability of elastomeric polymer alloy composed of segmented polyurethane and phospholipid polymer.

    PubMed

    Ogawa, Ryo; Iwasaki, Yasuhiko; Ishihara, Kazuhiko

    2002-11-01

    To develop a thermoplastic elastomer with high blood compatibility, a 2-methacryloyloxyethyl phosphorylcholine (MPC) polymer was blended with the segmented polyurethane (SPU) for preparing the polymer alloy. A tensile strength measurement was carried out to evaluate its mechanical strength. The mechanical strength of the SPU/MPC polymer alloy is the same as that of the original SPU and sufficient for use in medical applications. The thermal properties of the polymer alloy were evaluated by differential scanning calorimetry (DSC). The DSC curves indicated that the MPC polymer blended into the SPU did not affect the hard segment domain of the SPU. The SPU/MPC polymer alloy can be processed by heat treatment at 150 degrees C. Even after heat treatment, the SPU/MPC polymer alloy showed good mechanical properties, and MPC units were observed on the surface. Protein adsorption from human plasma was observed to evaluate the blood compatibility of the polymer alloy. The SPU/MPC polymer alloy suppressed protein adsorption on the surface before and after the heat treatment. Based on these results, it is concluded that the SPU/MPC polymer alloy has an excellent potential for application in various medical devices. PMID:12209941

  14. A Graduate Course in Polymer Processing.

    ERIC Educational Resources Information Center

    Middleman, Stanley

    1978-01-01

    This course, offered by the departments of chemical engineering and polymer science and engineering at the University of Massachusetts, is mainly a course in applied fluid dynamics with an emphasis on flow pressures dominated by viscous effects. (BB)

  15. Continuous process to produce lithium-polymer batteries

    DOEpatents

    Chern, T.S.H.; Keller, D.G.; MacFadden, K.O.

    1998-05-12

    Solid polymer electrolytes are extruded with active electrode material in a continuous, one-step process to form composite electrolyte-electrodes ready for assembly into battery cells. The composite electrolyte electrode sheets are extruded onto current collectors to form electrodes. The composite electrodes, as extruded, are electronically and ionically conductive. The composite electrodes can be over coated with a solid polymer electrolyte, which acts as a separator upon battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte separator has low resistance. 1 fig.

  16. Continuous process to produce lithium-polymer batteries

    DOEpatents

    Chern, Terry Song-Hsing; Keller, David Gerard; MacFadden, Kenneth Orville

    1998-01-01

    Solid polymer electrolytes are extruded with active electrode material in a continuous, one-step process to form composite electrolyte-electrodes ready for assembly into battery cells. The composite electrolyte-electrode sheets are extruded onto current collectors to form electrodes. The composite electrodes, as extruded, are electronically and ionically conductive. The composite electrodes can be overcoated with a solid polymer electrolyte, which acts as a separator upon battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte separator has low resistance.

  17. Solid electrolyte material manufacturable by polymer processing methods

    DOEpatents

    Singh, Mohit; Gur, Ilan; Eitouni, Hany Basam; Balsara, Nitash Pervez

    2012-09-18

    The present invention relates generally to electrolyte materials. According to an embodiment, the present invention provides for a solid polymer electrolyte material that is ionically conductive, mechanically robust, and can be formed into desirable shapes using conventional polymer processing methods. An exemplary polymer electrolyte material has an elastic modulus in excess of 1.times.10.sup.6 Pa at 90 degrees C. and is characterized by an ionic conductivity of at least 1.times.10.sup.-5 Scm-1 at 90 degrees C. An exemplary material can be characterized by a two domain or three domain material system. An exemplary material can include material components made of diblock polymers or triblock polymers. Many uses are contemplated for the solid polymer electrolyte materials. For example, the present invention can be applied to improve Li-based batteries by means of enabling higher energy density, better thermal and environmental stability, lower rates of self-discharge, enhanced safety, lower manufacturing costs, and novel form factors.

  18. Growing perovskite into polymers for easy-processable optoelectronic devices.

    PubMed

    Masi, Sofia; Colella, Silvia; Listorti, Andrea; Roiati, Vittoria; Liscio, Andrea; Palermo, Vincenzo; Rizzo, Aurora; Gigli, Giuseppe

    2015-01-01

    Here we conceive an innovative nanocomposite to endow hybrid perovskites with the easy processability of polymers, providing a tool to control film quality and material crystallinity. We verify that the employed semiconducting polymer, poly[2-methoxy-5-(2-ethylhexyloxy)-1,4-phenylenevinylene] (MEH-PPV), controls the self-assembly of CH₃NH₃PbI₃ (MAPbI₃) crystalline domains and favors the deposition of a very smooth and homogenous layer in one straightforward step. This idea offers a new paradigm for the implementation of polymer/perovskite nanocomposites towards versatile optoelectronic devices combined with the feasibility of mass production. As a proof-of-concept we propose the application of such nanocomposite in polymer solar cell architecture, demonstrating a power conversion efficiency up to 3%, to date the highest reported for MEH-PPV. On-purpose designed polymers are expected to suit the nanocomposite properties for the integration in diverse optoelectronic devices via facile processing condition. PMID:25579988

  19. Metal particle compaction during drop-substrate impact for inkjet printing and drop-casting processes

    NASA Astrophysics Data System (ADS)

    Clancy, I.; Amarandei, G.; Nash, C.; Glowacki, B. A.

    2016-02-01

    Direct coating methods using metal particles from aqueous solutions or solvent-based inks become central in the roll-to-roll fabrication processes as these methods can lead to continuous or pre-defined conductive layers on a large variety of substrates. For good electrical conductivity, the metal particles have to be brought into contact, and traditionally, additional sintering treatments are required. Such treatments can degrade the sensitive substrates as paper or polymer films. In this study, the possibility of obtaining conductive layers at room temperature is investigated for direct coating methods with an emphasis on drop-casting and inkjet printing. Thus, it is shown that electrical conductive layers can be achieved if the metal particles can compact during the drop-substrate impact interaction. It is theoretically shown that the compaction process is directly related to the particle and ink drop size, the initial fractional particle loading of the ink, solvent viscosity, and drop velocity. The theoretical predictions on compaction are experimentally validated, and the particle compaction's influence on changes in the electrical conductivity of the resulting layers is demonstrated.

  20. Using Synchrotron Radiation to Study Polymer Processing

    NASA Astrophysics Data System (ADS)

    Ryan, Anthony J.

    1998-03-01

    The growth of polymer crystals is well established in the literature and there are reliable theories to predict their kinetics, understanding of the initiation, or nucleation, step remains a mystery. Understanding this step should provide us with insights to the final morphology, and is thus essential to a complete understanding of polymer crystallisation. To probe nucleation behavior, slow, isothermal crystallisations with long induction times were studied by simultaneous, time-resolved SAXS and WAXS. These experiments show clear development of small angle scattering, due to the density fluctuations, with a characteristic length scale of 100 Angstroms, prior to the presence of crystals identified by wide-angle scattering. Once wide-angle diffraction from crystals (atomic order on the 1 Angstrom scale) was observed the kinetics reverted to those of nucleation and growth. This type of behaviour has also been observed in PET and PEEK. X-ray studies during tape extrusion also show SAXS patterns developing before the WAXS patterns. New experimental results for crystallisation of polymers in elongational and shear flow, as well as the quiescent state, will be presented along with a new model for nucleation in polymer crystallisation.

  1. Electric Field-Mediated Processing of Polymers. Appendix 1

    NASA Technical Reports Server (NTRS)

    Wnek, G. E.; Bowlin, G. L.; Haas, T. W.

    2000-01-01

    Significant opportunities exist for the processing of polymers (homopolymers and blends) using electric fields. We suggest that a broad range of properties can be achieved using a relatively small number of polymers, with electric fields providing the ability to tailor properties via the control of shape, morphology, and orientation. Specific attention is given to electrospinning, but we note that electroaerosol formation and field-modulated film casting represent additional processing options.

  2. High-efficiency solution processable polymer photovoltaic cells by self-organization of polymer blends

    NASA Astrophysics Data System (ADS)

    Li, Gang; Shrotriya, Vishal; Huang, Jinsong; Yao, Yan; Moriarty, Tom; Emery, Keith; Yang, Yang

    2005-11-01

    Converting solar energy into electricity provides a much-needed solution to the energy crisis the world is facing today. Polymer solar cells have shown potential to harness solar energy in a cost-effective way. Significant efforts are underway to improve their efficiency to the level of practical applications. Here, we report highly efficient polymer solar cells based on a bulk heterojunction of polymer poly(3-hexylthiophene) and methanofullerene. Controlling the active layer growth rate results in an increased hole mobility and balanced charge transport. Together with increased absorption in the active layer, this results in much-improved device performance, particularly in external quantum efficiency. The power-conversion efficiency of 4.4% achieved here is the highest published so far for polymer-based solar cells. The solution process involved ensures that the fabrication cost remains low and the processing is simple. The high efficiency achieved in this work brings these devices one step closer to commercialization.

  3. Polymer electroluminescent devices processed by inkjet printing: I. Polymer light-emitting logo

    NASA Astrophysics Data System (ADS)

    Bharathan, Jayesh; Yang, Yang

    1998-05-01

    Inkjet printing (IJP) technology is a popular technology for desktop publishing. Since some of the conducting (or conjugated) polymers are solution processable, IJP technology becomes an ideal method for printing polymer light-emitting diodes with high resolution. Unfortunately, the polymer film printed from an inkjet printer usually consists of pin-holes, and this intrinsic character makes it unsuitable for fabricating high quality polymer electronic devices, particularly for devices in the sandwich structure. In this letter, we submit a hybrid structure, which consists of an inkjet printed layer in conjunction with another uniform spin coated polymer layer, as an alternative to the regular inkjet printed structure. The uniform layer serves as a buffer layer to seal the pin-holes and the IJP layer is the layer consisting of the desired pattern, for example the red-green-blue dots for a multicolor display. To demonstrate, we applied this hybrid technology to fabricate efficient and large area polymer light-emitting logos. The use of this concept represents a whole new technology of fabricating polymer electronic devices with lateral patterning capability.

  4. All-polymer based fabrication process for an all-polymer flexible and parallel optical interconnect

    NASA Astrophysics Data System (ADS)

    Yang, Jilin; Ge, Tao; Summitt, Chris; Wang, Sunglin; Milster, Tom; Takashima, Yuzuru

    2015-08-01

    We proposed and demonstrated a new all-polymer based fabrication process for an all-polymer flexible and parallel optical interconnect cable in which a vertical light coupler is integrated. The approach potentially cut down the cost by eliminating a metallization process for alignment of multiple masks. Throughout the process we used a polyimide as the substrate, coated by Epoclad as claddings, then AP2210B and WPR 5100 were used to fabricate waveguides and 45 degree mirror couplers, respectively. In addition, precisely aligned mirror couplers to waveguides are achieved by using polymer-based, non-metallic, and transparent phase-based alignment marks. We tested a feature specific phase-based alignment system. In addition, the shape and depth of the phase-based alignment marks are optimized for phase contrast and Schlieren imaging. Our results shows that a contrast of the image is enhanced compared to that of observed by a conventional imaging system. Such process enables to integrate polymer based waveguides by only using the polymer based alignment marks on the WPR 5100 layer.

  5. Collaborative Investigations of Supramolecular Polymer Assembly Processes.

    NASA Astrophysics Data System (ADS)

    Wooley, Karen

    2007-03-01

    It is a pleasure to participate in this symposium, honoring Darrin J. Pochan's awarding of the John H. Dillon Medal for advancing our understanding of the physics of assembly and chain conformation of synthetic polypeptides. Assemblies of polypeptides, polysaccharides and polymers of nucleic acids are, of course, complex natural systems that form the bases of life. Over the past three years, we have worked together as a highly interdisciplinary team of investigators, to investigate the self assembly behaviors and resulting morphologies for synthetic amphiphilic block copolymer systems. This presentation will highlight the findings from these collaborative studies, including the importance of the block copolymer composition and topology and the significance of the assembly conditions.

  6. Azobenzene-based supramolecular polymers for processing MWCNTs

    NASA Astrophysics Data System (ADS)

    Maggini, Laura; Marangoni, Tomas; Georges, Benoit; Malicka, Joanna M.; Yoosaf, K.; Minoia, Andrea; Lazzaroni, Roberto; Armaroli, Nicola; Bonifazi, Davide

    2012-12-01

    Photothermally responsive supramolecular polymers containing azobenzene units have been synthesised and employed as dispersants for multi-walled carbon nanotubes (MWCNTs) in organic solvents. Upon triggering the trans-cis isomerisation of the supramolecular polymer intermolecular interactions between MWCNTs and the polymer are established, reversibly affecting the suspensions of the MWCNTs, either favouring it (by heating, i.e. cis --> trans isomerisation) or inducing the CNTs' precipitation (upon irradiation, trans --> cis isomerisation). Taking advantage of the chromophoric properties of the molecular subunits, the solubilisation/precipitation processes have been monitored by UV-Vis absorption spectroscopy. The structural properties of the resulting MWCNT-polymer hybrid materials have been thoroughly investigated via thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and atomic force microscopy (AFM) and modelled with molecular dynamics simulations.Photothermally responsive supramolecular polymers containing azobenzene units have been synthesised and employed as dispersants for multi-walled carbon nanotubes (MWCNTs) in organic solvents. Upon triggering the trans-cis isomerisation of the supramolecular polymer intermolecular interactions between MWCNTs and the polymer are established, reversibly affecting the suspensions of the MWCNTs, either favouring it (by heating, i.e. cis --> trans isomerisation) or inducing the CNTs' precipitation (upon irradiation, trans --> cis isomerisation). Taking advantage of the chromophoric properties of the molecular subunits, the solubilisation/precipitation processes have been monitored by UV-Vis absorption spectroscopy. The structural properties of the resulting MWCNT-polymer hybrid materials have been thoroughly investigated via thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and atomic force microscopy

  7. Advanced Process Model for Polymer Pyrolysis and Uranium Ceramic Material Processing

    SciTech Connect

    Wang, Xiaolin; Zunjarrao, Suraj C.; Zhang, Hui; Singh, Raman P.

    2006-07-01

    Silicon carbide (SiC) based uranium ceramic material can be fabricated as hosts for ultra high temperature applications, such as gas-cooled fast reactor fuels and in-core materials. A pyrolysis-based material processing technique allows for the fabrication of SiC based uranium ceramic materials at a lower temperature compared to sintering route. Modeling of the process is considered important for optimizing the fabrication and producing material with high uniformity. This study presents a process model describing polymer pyrolysis and uranium ceramic material processing, including heat transfer, polymer pyrolysis, SiC crystallization, chemical reactions, and species transport of a porous uranium oxide mixed polymer. Three key reactions for polymer pyrolysis and one key reaction for uranium oxide polymer interaction are established for the processing. Included in the model formulation are the effects of transport processes such as heat-up, polymer decomposition, and volatiles escape. The model is capable of accurately predicting the polymer pyrolysis and chemical reactions of the source material. Processing of a sample with certain geometry is simulated. The effects of heating rate, particle size and volume ratio of uranium oxide and polymer on porosity evolution, species uniformity, reaction rate are investigated. (authors)

  8. Chemical surface modification of fluorocarbon polymers by excimer laser processing

    NASA Astrophysics Data System (ADS)

    Niino, Hiroyuki; Yabe, Akira

    1996-04-01

    Surface of poly(tetrafluoroethylene) [PTFE] film was modified chemically by an ArF excimer laser-induced reaction in a hydrazine gas atmosphere. The polymer surface modified upon the irradiation of 1000 pulses at 27 mJ cm -2, which was a fairly lower fluence than the ablation threshold for usual polymer films, showed hydrophilicity (contact angle for water: 30°) enough to be metallized by chemical plating. The mechanism for chemical surface modification was investigated by FTIR, XPS, and SIMS analyses. The laser-treated PTFE film was metallized by a chemical plating process. These processes will be used to fabricate printed wiring boards for high frequency electronics.

  9. Growing perovskite into polymers for easy-processable optoelectronic devices

    NASA Astrophysics Data System (ADS)

    Masi, Sofia; Colella, Silvia; Listorti, Andrea; Roiati, Vittoria; Liscio, Andrea; Palermo, Vincenzo; Rizzo, Aurora; Gigli, Giuseppe

    2015-01-01

    Here we conceive an innovative nanocomposite to endow hybrid perovskites with the easy processability of polymers, providing a tool to control film quality and material crystallinity. We verify that the employed semiconducting polymer, poly[2-methoxy-5-(2-ethylhexyloxy)-1,4-phenylenevinylene] (MEH-PPV), controls the self-assembly of CH3NH3PbI3 (MAPbI3) crystalline domains and favors the deposition of a very smooth and homogenous layer in one straightforward step. This idea offers a new paradigm for the implementation of polymer/perovskite nanocomposites towards versatile optoelectronic devices combined with the feasibility of mass production. As a proof-of-concept we propose the application of such nanocomposite in polymer solar cell architecture, demonstrating a power conversion efficiency up to 3%, to date the highest reported for MEH-PPV. On-purpose designed polymers are expected to suit the nanocomposite properties for the integration in diverse optoelectronic devices via facile processing condition.

  10. Growing perovskite into polymers for easy-processable optoelectronic devices

    PubMed Central

    Masi, Sofia; Colella, Silvia; Listorti, Andrea; Roiati, Vittoria; Liscio, Andrea; Palermo, Vincenzo; Rizzo, Aurora; Gigli, Giuseppe

    2015-01-01

    Here we conceive an innovative nanocomposite to endow hybrid perovskites with the easy processability of polymers, providing a tool to control film quality and material crystallinity. We verify that the employed semiconducting polymer, poly[2-methoxy-5-(2-ethylhexyloxy)-1,4-phenylenevinylene] (MEH-PPV), controls the self-assembly of CH3NH3PbI3 (MAPbI3) crystalline domains and favors the deposition of a very smooth and homogenous layer in one straightforward step. This idea offers a new paradigm for the implementation of polymer/perovskite nanocomposites towards versatile optoelectronic devices combined with the feasibility of mass production. As a proof-of-concept we propose the application of such nanocomposite in polymer solar cell architecture, demonstrating a power conversion efficiency up to 3%, to date the highest reported for MEH-PPV. On-purpose designed polymers are expected to suit the nanocomposite properties for the integration in diverse optoelectronic devices via facile processing condition. PMID:25579988

  11. Numerical Study of Thrust Generation in the Process of Laser Ablated Doped Polymer

    NASA Astrophysics Data System (ADS)

    Li, Nanlei; Hong, Yanji; Li, Xiuqian

    2011-11-01

    Recoil impulse of ablation products is a dominant source of thrust during laser ablation of polymers in vacuum. Based on the experiment phenomenon, put forward the threshold energy model to described ablation process, used laser deposition energy in polymer as ablation criterion, and calculated the fluence of energy generation from polymer chemolysis. Take the doped polymer PVC as research object, analyzed and computed interested parameter in process of laser ablated polymer, such as exhaust velocities of ablated product, ablated mass of polymer, recoil momentum gained by polymer target. Consulted experiment data, the numerical model well revealed the propulsion capability of different polymers.

  12. Radiation processing of natural polymers: The IAEA contribution

    NASA Astrophysics Data System (ADS)

    Haji-Saeid, Mohammad; Safrany, Agnes; Sampa, Maria Helena de O.; Ramamoorthy, Natesan

    2010-03-01

    Radiation processing offers a clean and additive-free method for preparation of value-added novel materials based on renewable, non-toxic, and biodegradable natural polymers. Crosslinked natural polymers can be used as hydrogel wound dressings, face cleaning cosmetic masks, adsorbents of toxins, and non-bedsore mats; while low molecular weight products show antibiotic, antioxidant, and plant-growth promoting properties. Recognizing the potential benefits that radiation technology can offer for processing of natural polymers into useful products, the IAEA implemented a coordinated research project (CRP) on "Development of Radiation-processed products of Natural Polymers for application in Agriculture, Healthcare, Industry and Environment". This CRP was launched at the end of 2007 with participation of 16 MS to help connecting radiation technology and end-users to derive enhanced benefits from these new value-added products of radiation-processed natural materials. In this paper the results of activities in participating MS related to this work will be presented.

  13. Processing-structure-property relationships in oriented polymers

    NASA Astrophysics Data System (ADS)

    Xia, Zhiyong

    The Processing-Structure-Property (P-S-P) relationships in oriented polymers have been studied in this dissertation. Controlled polymer orientation has been achieved through the equal channel angular extrusion (ECAE) process. The structure of the ECAE-oriented polymers have been investigated from all dimensional levels, i.e., from spherulitical scale (micrometer scale), lamellar scale (nanometer scale) to crystallographic scale (angstrom scale). The results indicate that the polymer spherulites are deformed into macrofibrils after one ECAE process. Within the macrofibrils, a "V-type" lamellar orientation has been formed to accommodate the overall straining of spherulites. The molecular chains in the crystalline lamellae are found to be tilted at a small angle with respect to the lamellar surface. Whereas, the molecular chains between the macrofibrils and crystalline lamellae are highly stretched. Property characterization indicates that ECAE-induced microstructure is responsible for the improved physical and mechanical properties. The improved physical and mechanical properties include high tensile modulus, higher impact fracture toughness and better scratch resistance. This research has also clarified several controversies in the research of semicrystalline polymers. First, this research gives an unambiguous account on the lamellar evolution during large-scale plastic deformation. The crystalline lamellae in the ECAE-oriented samples have been found to be evolved from the original crystalline lamellae. Secondly, the shifting of the primary relaxation peak in ECAE-oriented PET has been found to be due to the increase in molecular orientation. Thirdly, the transmission electron microscopy (TEM) indicates that in low crystallinity semicrystalline polymers, the larger value of the two characteristic lengths from small angle X-ray scattering (SAXS) correlation function analysis should be assigned to the crystalline lamellar thickness.

  14. Process for recovering filler from polymer

    DOEpatents

    Smith, Maurice L.; Smith, Robert M.

    1978-01-01

    This disclosure relates to a process for recovering filler material from a polymeric matrix by reacting the matrix at an elevated temperature in a gas atmosphere with a controlled oxidizing potential and thereafter separating and cleaning the residue from the reaction mixture.

  15. n-Type Water/Alcohol-Soluble Naphthalene Diimide-Based Conjugated Polymers for High-Performance Polymer Solar Cells.

    PubMed

    Wu, Zhihong; Sun, Chen; Dong, Sheng; Jiang, Xiao-Fang; Wu, Siping; Wu, Hongbin; Yip, Hin-Lap; Huang, Fei; Cao, Yong

    2016-02-17

    organic photovoltaic modules based on roll-to-roll coating processes. PMID:26794827

  16. Polymerization and processing of organic polymers in a magnetic field

    SciTech Connect

    Douglas, E.P.

    1995-05-01

    The use of magnetic fields to affect the structure and properties of polymeric materials remains an area of great promise. Liquid crystalline polymers have been actively studied over the past 20 years for use in high performance structural applications. In particular, highly oriented fibers can exhibit remarkable increases in strength to weight performance compared to conventional materials. For example, the fibers marketed by DuPont under the tradename Kevlar are 20 times stronger than steel on an equivalent weight basis. However, larger bulk parts do not exhibit the same increases in strength due to a lack of orientation of the polymer molecules. Magnetic field processing of polymers remains an attractive solution to this problem.

  17. Diorganosilacetylene-alt-diorganosilvinylene polymers and a process of preparation

    DOEpatents

    Barton, Thomas J.; Ijadi-Maghsoodi, Sina; Pang, Yi

    1993-08-31

    The present invention provides linear organosilicon polymers including acetylene and vinylene moieties, and a process for their preparation. These diorganosilacetylenealt-diorganosilvinylene linear polymers can be represented by the formula: --[--(R.sup.1)(R.sup.2)Si--C.ident.C--(R.sup.3)(R.sup.4)Si--CH=CH--].sub.n --, wherein n.gtoreq.2; each R.sup.1, R.sup.2, R.sup.3, and R.sup.4 is independently selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, aryl, and aralkyl radicals. The polymers are soluble in organic solvents, air stable, and can be pulled into fibers or cast into films. They can be thermally converted into silicon carbide ceramic materials.

  18. Diorganosilacetylene-alt-diorganosilvinylene polymers and a process of preparation

    DOEpatents

    Barton, T.J.; Ijadi-Maghsoodi, S.; Pang, Y.

    1995-10-10

    The present invention provides linear organosilicon polymers including acetylene and vinylene moieties, and a process for their preparation. These diorganosilacetylene-alt-diorganosilvinylene linear polymers can be represented by the formula: --[--(R{sup 1})(R{sup 2})Si--C{triple_bond}C--(R{sup 3})(R{sup 4})Si--CH{double_bond}CH--]{sub n}--, wherein n{>=}2; and each R{sup 1}, R{sup 2}, R{sup 3}, and R{sup 4} is independently selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, aryl, and aralkyl radicals. The polymers are soluble in organic solvents, air stable, and can be pulled into fibers or cast into films. They can be thermally converted into silicon carbide ceramic materials.

  19. Diorganosilacetylene-alt-diorganosilvinylene polymers and a process of preparation

    DOEpatents

    Barton, Thomas J.; Ijadi-Maghsoodi, Sina; Pang, Yi

    1995-10-10

    The present invention provides linear organosilicon polymers including acetylene and vinylene moieties, and a process for their preparation. These diorganosilacetylene-alt-diorganosilvinylene linear polymers can be represented by the formula: --[--(R.sup.1)(R.sup.2)Si--C.tbd.C--(R.sup.3)(R.sup.4)Si--CH.dbd.CH--].sub .n --, wherein n.gtoreq.2; and each R.sup.1, R.sup.2, R.sup.3, and R.sup.4 is independently selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, aryl, and aralkyl radicals. The polymers are soluble in organic solvents, air stable, and can be pulled into fibers or cast into films. They can be thermally converted into silicon carbide ceramic materials.

  20. Diorganosilacetylene-alt-diorganosilvinylene polymers and a process of preparation

    DOEpatents

    Barton, T.J.; Ijadi-Maghsoodi, S.; Yi Pang.

    1993-08-31

    The present invention provides linear organosilicon polymers including acetylene and vinylene moieties, and a process for their preparation. These diorganosilacetylene-alt-diorganosilvinylene linear polymers can be represented by the formula: -[-(R[sup 1])(R[sup 2])Si-C[triple bond]C-(R[sup 3])(R[sup 4])Si-CH[double bond]CH-][sub n]-, wherein n[>=]2; each R[sup 1], R[sup 2], R[sup 3], and R[sup 4] is independently selected from the group consisting of hydrogen, halogen, alkyl, alkenyl, aryl, and aralkyl radicals. The polymers are soluble in organic solvents, air stable, and can be pulled into fibers or cast into films. They can be thermally converted into silicon carbide ceramic materials.

  1. Laser processing of components for polymer mircofluidic and optoelectronic products

    NASA Astrophysics Data System (ADS)

    Gillner, Arnold; Bremus-Koebberling, Elke A.; Wehner, Martin; Russek, Ulrich A.; Berden, Thomas

    2001-06-01

    Miniaturization is one of the keywords for the production of customer oriented and highly integrated consumer products like mobile phones, portables and other products from the daily life and there are some first silicon made products like pressure sensors, acceleration sensors and micro fluidic components, which are built in automobiles, washing machines and medical products. However, not all applications can be covered with this material, because of the limitations in lateral and 3-dimensional structuring, the mechanical behavior, the functionality and the costs of silicon. Therefore other materials, like polymers have been selected as suitable candidates for cost effective mass products. This holds especially for medical and optical applications, where the properties of selected polymers, like biocompatibility, inert chemical behavior and high transparency can be used. For this material laser micro processing offers appropriate solutions for structuring as well as for packaging with high flexibility, material variety, structure size, processing speed and easy integration into existing fabrication plants. The paper presents recent results and industrial applications of laser micro processing for polymer micro fluidic devices, like micro analysis systems, micro reactors and medical micro implants, where excimer radiation is used for lateral structuring and diode lasers have used for joining and packaging. Similar technologies have been applied to polymer waveguides to produce passive optoelectronic components for high speed interconnection with surface roughness less than 20 nm and low attenuation. The paper also reviews the technical and economical limitations and the potential of the technology for other micro products.

  2. Tough, processable semi-interpenetrating polymer networks from monomer reactants

    NASA Technical Reports Server (NTRS)

    Pater, Ruth H. (Inventor)

    1994-01-01

    A high temperature semi-interpenetrating polymer network (semi-IPN) was developed which had significantly improved processability, damage tolerance, and mechanical performance, when compared to the commercial Thermid materials. This simultaneous semi-IPN was prepared by mixing the monomer precursors of Thermid AL-600 (a thermoset) and NR-150B2 (a thermoplastic) and allowing the monomers to react randomly upon heating. This reaction occurs at a rate which decreases the flow and broadens the processing window. Upon heating at a higher temperature, there is an increase in flow. Because of the improved flow properties, broadened processing window and enhanced toughness, high strength polymer matrix composites, adhesives and molded articles can now be prepared from the acetylene end-capped polyimides which were previously inherently brittle and difficult to process.

  3. Nonlinear optical polymers for electro-optic signal processing

    NASA Technical Reports Server (NTRS)

    Lindsay, Geoffrey A.

    1991-01-01

    Photonics is an emerging technology, slated for rapid growth in communications systems, sensors, imagers, and computers. Its growth is driven by the need for speed, reliability, and low cost. New nonlinear polymeric materials will be a key technology in the new wave of photonics devices. Electron-conjubated polymeric materials offer large electro-optic figures of merit, ease of processing into films and fibers, ruggedness, low cost, and a plethora of design options. Several new broad classes of second-order nonlinear optical polymers were developed at the Navy's Michelson Laboratory at China Lake, California. Polar alignment in thin film waveguides was achieved by electric-field poling and Langmuir-Blodgett processing. Our polymers have high softening temperatures and good aging properties. While most of the films can be photobleached with ultraviolet (UV) light, some have excellent stability in the 500-1600 nm range, and UV stability in the 290-310 nm range. The optical nonlinear response of these polymers is subpicosecond. Electro-optic switches, frequency doublers, light modulators, and optical data storage media are some of the device applications anticipated for these polymers.

  4. Chemistry and processing of polymer shells

    NASA Astrophysics Data System (ADS)

    Alfonso, Emmanuel Limjuco

    The fabrication of high-quality spherical shells, used as fuel capsules in fusion experiments, is essential to the progress of the inertial confinement fusion program. Two types of shell were produced: (1) Polystyrene shells were made in a microencapsulation method. The yield, diameter, wall thickness, vacuole content, and surface finish were determined for shells prepared with an organic phase of toluene and 1,2-dichloroethane with polystyrene concentrations varied from 5 to 13 wt% and an internal water phase that sometimes contained surfactants. (2) Polyimide shells were made by vapor-phase deposition onto depolymerizable spherical mandrels. High-aspect-ratio polyimide shells with diameters ranging from 700 to 1000 mum and wall thicknesses from 2 to 13 mum have been fabricated. Estimates of the composition, surface roughness, burst and buckle pressures, elastic modulus, tensile strength, permeability, and film stress have been obtained. These shells have been characterized in terms of morphological properties: the shell dimensions (diameter and wall thickness), sphericity, wall structure, outer and inner surface finish, and transparency. The structure of the outer surface and wall cross section varied strongly with the processing conditions (e.g., deposition temperatures, system pressure), while the inner surface was shown to be very smooth. The transparency of near-stoichiometric polyimide shells and flat films was demonstrated. Rutherford backscattering and nuclear resonance analysis techniques were used to provide the elemental composition and density, which were very near the theoretical values. Polyimide shells' minimum tensile strengths and moduli were determined from burst and buckle pressure tests. The tensile strength approached that reported for Kapton-HN film. The elastic moduli varied with processing conditions. The vapor-deposited polyimide was found to possess mechanical strength properties similar to commercially available polyimides. The room

  5. Linear and nonlinear optical processing of polymer matrix nanocomposites

    NASA Astrophysics Data System (ADS)

    DeJournett, Travis J.; Han, Karen; Olasov, Lauren R.; Zeng, Fan W.; Lee, Brennan; Spicer, James B.

    2015-08-01

    This work focuses on the scalable synthesis and processing of nanostructures in polymer matrix nanocomposites (PMNCs) for applications that require photochemical functionality of these nanostructures. An in situ vapor deposition process using various metal and metal oxide precursors has been used to create a range of nanocomposites that display photochromic and photocatalytic behaviors. Under specific processing conditions, these composites consist of discrete nanoparticles distributed uniformly throughout the bulk of an optically transparent polymer matrix. Incorporating other chemical species as supplementary deposition agents in the synthesis process can modify these particles and produce complicated nanostructures with enhanced properties. In particular, work has been carried out to structure nanoparticles using laser irradiation. Starting with metallic or metal oxide nanoparticles in the polymer matrix, localized chemical vapor deposition in the near-particle environment has been carried out using laser irradiation to decompose chemical precursors leading to the formation of secondary structures surrounding the seed nanoparticles. Control of the spatial and temporal characteristics of the excitation source allows for synthesis of nanocomposites with a high degree of control over the location, composition and size of nanoparticles in the matrix and presents the opportunity to produce patterned materials with spatially varying properties.

  6. Glass transition and relaxation processes of nanocomposite polymer electrolytes.

    PubMed

    Money, Benson K; Hariharan, K; Swenson, Jan

    2012-07-01

    This study focus on the effect of δ-Al(2)O(3) nanofillers on the dc-conductivity, glass transition, and dielectric relaxations in the polymer electrolyte (PEO)(4):LiClO(4). The results show that there are three dielectric relaxation processes, α, β, and γ, in the systems, although the structural α-relaxation is hidden in the strong conductivity contribution and could therefore not be directly observed. However, by comparing an enhanced dc-conductivity, by approximately 2 orders of magnitude with 4 wt % δ-Al(2)O(3) added, with a decrease in calorimetric glass transition temperature, we are able to conclude that the dc-conductivity is directly coupled to the hidden α-relaxation, even in the presence of nanofillers (at least in the case of δ-Al(2)O(3) nanofillers at concentrations up to 4 wt %). This filler induced speeding up of the segmental polymer dynamics, i.e., the α-relaxation, can be explained by the nonattractive nature of the polymer-filler interactions, which enhance the "free volume" and mobility of polymer segments in the vicinity of filler surfaces. PMID:22686254

  7. Nano-structured polymer composites and process for preparing same

    DOEpatents

    Hillmyer, Marc; Chen, Liang

    2013-04-16

    A process for preparing a polymer composite that includes reacting (a) a multi-functional monomer and (b) a block copolymer comprising (i) a first block and (ii) a second block that includes a functional group capable of reacting with the multi-functional monomer, to form a crosslinked, nano-structured, bi-continuous composite. The composite includes a continuous matrix phase and a second continuous phase comprising the first block of the block copolymer.

  8. Synthesis and characterization of thiol-functionalized polymer as binder in conductive ink

    NASA Astrophysics Data System (ADS)

    Lee, Jungmin; Varadan, Vijay K.

    2011-04-01

    The technology of electrical printing has received industrial and scientific attention due to wide variety of application such as sensors, radio frequency identification cards (RFIDs), flexible display, and flexible solar cell. Especially a roll to roll gravure printing technique has been useful for mass production of electrical products. For the more high quality of conductive ink, the compatibility of organic binder and inorganic filler is very important. In this study, Thiol-functionalized polymer and core-shell conductive nanoparticles were used as the binder and filler. The thiol moieties in binder contribute to functionality of the synthesized polymer. Also, the conductivity and viscosity of synthesized ink and compatibility of filler with binder were characterized in various conditions.

  9. The Rheology and Processing of Renewable Resource Polymers

    NASA Astrophysics Data System (ADS)

    Conrad, Jason D.; Harrison, Graham M.

    2008-07-01

    Bio-based polymers offer an alternative to conventional fossil fuel-based materials, in particular for commodity applications such as single-use products. In this work, we report on the rheology and processing of two bio-based polymers, namely poly-hydroxyalkanoate (PHA) copolymers and poly-lactic acid (PLA), and their blends. These materials are derived from renewable resources, and can degrade under the appropriate conditions. The rheology is investigated in shear, elongation, and transient modes. Of particular importance is the degradation of these materials at typical processing conditions, and the impact of polymer architecture on the extensional properties. Using results from these rheological investigations, appropriate thermal and flow conditions are employed in a DSM Xplore microcompounder, with the cast film attachment, to produce films of PHA copolymers blended with PLA. The resultant films are characterized, as a function of both material composition and processing history, using DSC, WAXD, tensile testing, and SEM, to investigate the effect of varying PHA content on the final properties.

  10. Impact of polymer film thickness and cavity size on polymer flow during embossing : towards process design rules for nanoimprint lithography.

    SciTech Connect

    Schunk, Peter Randall; King, William P. (Georgia Institute of Technology, Atlanta, GA); Sun, Amy Cha-Tien; Rowland, Harry D.

    2006-08-01

    This paper presents continuum simulations of polymer flow during nanoimprint lithography (NIL). The simulations capture the underlying physics of polymer flow from the nanometer to millimeter length scale and examine geometry and thermophysical process quantities affecting cavity filling. Variations in embossing tool geometry and polymer film thickness during viscous flow distinguish different flow driving mechanisms. Three parameters can predict polymer deformation mode: cavity width to polymer thickness ratio, polymer supply ratio, and Capillary number. The ratio of cavity width to initial polymer film thickness determines vertically or laterally dominant deformation. The ratio of indenter width to residual film thickness measures polymer supply beneath the indenter which determines Stokes or squeeze flow. The local geometry ratios can predict a fill time based on laminar flow between plates, Stokes flow, or squeeze flow. Characteristic NIL capillary number based on geometry-dependent fill time distinguishes between capillary or viscous driven flows. The three parameters predict filling modes observed in published studies of NIL deformation over nanometer to millimeter length scales. The work seeks to establish process design rules for NIL and to provide tools for the rational design of NIL master templates, resist polymers, and process parameters.

  11. Broader Understanding of Multiple Component Dynamic Processes in Miscible Polymer/Polymer Blends

    NASA Astrophysics Data System (ADS)

    Sharma, Ravi; Yang, Hengxi; Green, Peter

    Utilizing two different experimental techniques, isothermal frequency sweeps and isochronal temperature sweeps, in broadband dielectric spectroscopy can allow for the identification of multiple processes derived from the same relaxation mechanism in certain polymer/polymer blends. A study of poly(vinyl methyl ether) (PVME) in bulk, miscible blends with polystyrene (PS) gives evidence of two separate relaxation processes associated exclusively with the segmental dynamics of PVME; the α0 process from the temperature sweep, related to average segmental dynamics, and the α' process from the frequency sweep, related to relaxations confined within ``frozen'' domains. The appearance of multiple processes is driven by compositional heterogeneity, mainly chain connectivity and concentration fluctuation effects. Analysis of the breadth and intensity of the dielectric loss curves gives insight into the structure and thermodynamics of the blend, which in turn can explain temperature and composition dependent dynamic trends. These results are contrasted with other miscible blend systems, polyisoprene (PI)/poly(4-tert-butylstyrene) (P4tBS) and polyisoprene (PI)/polyvinyl ether (PVE).

  12. Interfacial Behavior of Polymers: Using Interfaces to Manipulate Polymers

    SciTech Connect

    Russell, Thomas P.

    2015-02-26

    most rapid solvent removal process drives the copolymer film to below its glass transition temperature, freezing in the lateral order. We have quantitatively described the ordering and the parameters influencing the disruption of the ordering in these studies. We have also used e-beam lithography to generate shallow trench patterns on planar surface where the topographic patterning provides an additional constraint on the self-assembly of the block copolymer. The pitches of the trenches were varied while the depth and the trench width of patterns were maintained by constant at 89 and 30nm, respectively. Unidirectional PS-b-PEO line patterns over large area on the shallow trench patterns were obtained by solvent vapor annealing. We extended the solvent annealing process to an in-line coating process using a mini-slot die coater developed in our laboratories. This coater uses minimal materials with operating parameters that can mimic actual industrial processing on a roll-to-roll line. Most important, with this mini-slot die coater, it could also characterize the structure of the film using grazing incidence x-ray scattering. Using the fundamental characterization of the ordering of the block copolymers, we could optimize the coating conditions to enhance lateral ordering of block copolymer in a well-defined manner. The structures produced in this process are directly transferable to flexible electronics where the arrays of block copolymer microdomains can be used for the fabrication of nanostructured components. We have also controlled the orientation of BCP microdomains at the air and substrate interfaces by manipulating the interfacial interactions with selective solvents. This has enabled us to generate nanoporous membranes where the size of the pores is dictated by the size of the bloc copolymer microdomains. We have produced robust nanoporous membranes that can tolerate high pressures and have high throughput using thick films of block copolymers. Exceptional size

  13. Process optimization of ultrasonic spray coating of polymer films.

    PubMed

    Bose, Sanjukta; Keller, Stephan S; Alstrøm, Tommy S; Boisen, Anja; Almdal, Kristoffer

    2013-06-11

    In this work we have performed a detailed study of the influence of various parameters on spray coating of polymer films. Our aim is to produce polymer films of uniform thickness (500 nm to 1 μm) and low roughness compared to the film thickness. The coatings are characterized with respect to thickness, roughness (profilometer), and morphology (optical microscopy). Polyvinylpyrrolidone (PVP) is used to do a full factorial design of experiments with selected process parameters such as temperature, distance between spray nozzle and substrate, and speed of the spray nozzle. A mathematical model is developed for statistical analysis which identifies the distance between nozzle and substrate as the most significant parameter. Depending on the drying of the sprayed droplets on the substrate, we define two broad regimes, "dry" and "wet". The optimum condition of spraying lies in a narrow window between these two regimes, where we obtain a film of desired quality. Both with increasing nozzle-substrate distance and temperature, the deposition moves from a wet state to a dry regime. Similar results are also achieved for solvents with low boiling points. Finally, we study film formation during spray coating with poly (D,L-lactide) (PDLLA). The results confirm the processing knowledge obtained with PVP and indicate that the observed trends are identical for spraying of other polymer films. PMID:23631433

  14. Mechanisms of shark skin suppression by novel polymer processing aids

    NASA Astrophysics Data System (ADS)

    Wagner, M. H.; Himmel, T.; Kulikov, O.; Hornung, K.

    2014-05-01

    The extrusion rate of polyethylene (PE) with narrow molar weight distribution, as e.g. metallocen catalysed polyethylene (m-PE), is limited by melt fracture. The first level of fracture is a surface defect called sharkskin. Common polymer processing aids based on fluorinated polymers shift the onset of sharkskin to higher extrusion rates by creating a "low energy surface" at the die wall and promoting wall slip. Alternatively, Kulikov et al. [1, 2] suggested thermoplastic elastomers (TPE) for sharkskin suppression, and Müller [3] showed the suitability of some TPEs as polymer processing aids. We investigated the slip velocity of several TPEs against steel, and the slip velocity in a polymeric interface between polyethylene (PE) and TPE by rotational plate-plate rheometry in the Newtonian flow regime. TPEs with lower viscosities showed higher slip velocities against steel. However, the interfacial slip velocities between PE and TPE were found to be viscosity independent. In both cases, the slip velocity was found to be proportional to the applied shear stress.

  15. Bridging Microstructure, Properties and Processing of Polymer Based Advanced Materials

    SciTech Connect

    Li, Dongsheng; Ahzi, Said; Khaleel, Mohammad A.

    2012-01-01

    This is a guest editorial for a special issue in Journal of Engineering Materials and Technology. The papers collected in this special issue emphasize significant challenges, current approaches and future strategies necessary to advance the development of polymer-based materials. They were partly presented at the symposium of 'Bridging microstructure, properties and processing of polymer based advanced materials' in the TMS 2011 annual conference meeting, which was held in San Diego, US, on Feb 28 to March 3, 2011. This symposium was organized by the Pacific Northwest National Laboratory (USA) and the Institute of Mechanics of Fluids and Solids of the University of Strasbourg (France). The organizers were D.S. Li, S. Ahzi, and M. Khaleel.

  16. Optical characterization of thin nickel films on polymer substrates using reflectance difference spectroscopy

    SciTech Connect

    Rinnerbauer, V.; Schmidegg, K.; Hohage, M.; Sun, L. D.; Flores-Camacho, J. M.; Zeppenfeld, P.

    2009-06-15

    We have used reflectance difference spectroscopy (RDS) and its extension, azimuth-dependent RDS (ADRDS), to study the properties of sputtered and evaporated nickel films on biaxially oriented poly(ethylene terephtalate) (PET) films in a roll to roll web-coating process. From the full set of ADRDS spectra we extract and analyze both the intrinsic RDS spectra and the azimuthal orientation of the effective optical anisotropy of the samples. From the latter, contributions to the RDS spectra arising from the nickel layer and the PET substrate with different orientations of the optical eigenaxes can be inferred. We find an attenuation of the characteristic RDS signal of the PET substrate with increasing nickel film thickness which is in good agreement with the theoretical prediction. For film thicknesses above 20 nm another contribution to the RDS signal attributed to the optical anisotropy of the deposited nickel layers can be observed. Its strength depends on the deposition method, and is considerably larger for evaporated films than for sputtered ones. With increasing nickel film thickness, the azimuthal orientation of the sample anisotropy changes from the initial value of the PET substrate by about 20 deg.toward the machine direction of the foil. We demonstrate that RDS is also a valuable tool for inline monitoring in the roll to roll process, as the attenuation of the RDS signal, under proper consideration of the orientation of the effective anisotropy, is a function of the film thickness and characteristic for the deposited material.

  17. A solid-state dye-sensitized solar cell based on a novel ionic liquid gel and ZnO nanoparticles on a flexible polymer substrate.

    PubMed

    Wei, Di; Unalan, Husnu Emrah; Han, Dongxue; Zhang, Qixian; Niu, Li; Amaratunga, Gehan; Ryhanen, Tapani

    2008-10-22

    This paper describes a new strategy to make a full solid-state, flexible, dye-sensitized solar cell (DSSC) based on novel ionic liquid gel, organic dye, ZnO nanoparticles and carbon nanotube (CNT) thin film stamped onto a polyethylene terephthalate (PET) substrate. The CNTs serve both as the charge collector and as scaffolds for the growth of ZnO nanoparticles, where the black dye molecules are anchored. It opens up the possibility of developing a continuous roll to roll processing for THE mass production of DSSCs. PMID:21832666

  18. Long-lived charge carrier dynamics in polymer/quantum dot blends and organometal halide perovskites

    NASA Astrophysics Data System (ADS)

    Nagaoka, Hirokazu

    Solution-processable semiconductors offer a potential route to deploy solar panels on a wide scale, based on the possibility of reduced manufacturing costs by using earth-abundant materials and inexpensive production technologies, such as inkjet or roll-to-roll printing. Understanding the fundamental physics underlying device operation is important to realize this goal. This dissertation describes studies of two kinds of solar cells: hybrid polymer/PbS quantum dot solar cells and organometal halide perovskite solar cells. Chapter two discusses details of the experimental techniques. Chapter three and four explore the mechanisms of charge transfer and energy transfer spectroscopically, and find that both processes contribute to the device photocurrent. Chapter four investigates the important question of how the energy level alignment of quantum dot acceptors affects the operation of hybrid polymer/quantum dot solar cells, by making use of the size-tunable energy levels of PbS quantum dots. We observe that long-lived charge transfer yield is diminished at larger dot sizes as the energy level offset at the polymer/quantum dot interface is changed through decreasing quantum confinement using a combination of spectroscopy and device studies. Chapter five discusses the effects of TiO2 surface chemistry on the performance of organometal halide perovskite solar cells. Specifically, chapter five studies the effect of replacing the conventional TiO2 electrode with Zr-doped TiO2 (Zr-TiO2). We aim to explore the correlation between charge carrier dynamics and device studies by incorporating zirconium into TiO2. We find that, compared to Zr-free controls, solar cells employing Zr-TiO2 give rise to an increase in overall power conversion efficiency, and a decrease in hysteresis. We also observe longer carrier lifetimes and higher charge carrier densities in devices on Zr-TiO2 electrodes at microsecond times in transient photovoltage experiments, as well as at longer persistent

  19. Removal of Pu-238 from aqueous process streams using a polymer filtration process

    NASA Astrophysics Data System (ADS)

    Jarvinen, Gordon D.; Purdy, Geraldine M.; Rau, Karen C.; Remeroski, M. L.; Reimus, Mary Ann H.; Ramsey, Kevin B.; Foltyn, Elizabeth M.; Smith, Barbara F.; Robison, Thomas W.

    2001-02-01

    A glovebox facility is under construction at Los Alamos that will recover a significant quantity of the impure Pu-238 that exists in scrap and residues from past production operations. The general flowsheet consists of milling, acid dissolution, ion exchange, precipitation, calcination, oxygen isotope exchange, and waste treatment operations. As part of the waste treatment operations we are using polymer filtration to remove Pu-238 to meet facility discharge limits. Polymer filtration (PF) technology uses water-soluble polymers prepared with selective receptor sites to sequester metal ions, organic molecules, and other species from dilute aqueous solutions. The water-soluble polymers have a sufficiently large molecular size that they can be separated and concentrated using ultrafiltration (UF) methods. Water and small, unbound components of the solution pass freely through the UF membrane while the polymer concentrates in the retentate. The permeate stream is ``cleaned'' of the components bound to the polymer and can be used in further processing steps or discharged. The concentrated retentate solution can be treated to give a final waste form or to release the sequestered species from the receptor sites by adjusting the conditions in the retentate solution. The PF technology is part of our work to develop a safe, reliable and cost-effective scrap recovery operation with high process efficiencies, minimal waste generation, and high product purity. .

  20. Exposure to chemical additives from polyvinyl chloride polymer extrusion processing

    SciTech Connect

    Lamb, C.S.

    1989-12-01

    The report presents a model to predict worker inhalation exposure due to off-gassing of additives during polyvinyl chloride (PVC) extrusion processing. Data on off-gassing of additives were reviewed in the literature, the off-gassing at normal PVC processing temperatures was studied in the laboratory, process variables were estimated from an equipment manufacturer survey, and worker-activities and possible exposure sources were observed in an industrial survey. The purpose of the study was to develop a theoretical model to predict worker inhalation exposure to additives used during PVC extrusion processing. A model to estimate the generation rate of the additive from the polymer extrudate was derived from the mass transport equations governing diffusion. The mass flow rate, initial additive volatile weight fraction, off-gassing time, diffusivity, and slab thickness are required to determine the generation rate from the model.

  1. Polymer performance in cooling water: The influence of process variables

    SciTech Connect

    Amjad, Z.; Pugh, J.; Zibrida, J.; Zuhl, B.

    1997-01-01

    The key to the efficacy of phosphate and phosphonates in stabilized phosphate and all-organic cooling water treatment (CWT) programs is the presence and performance of polymeric inhibitors/dispersants. The performance of polymeric additives used in CWT programs can be adversely impacted by the presence of iron, phosphonate, or cationic polymer and influenced by a variety of process variables including system pH and temperature. In this article, the performance of several polymeric additives is evaluated under a variety of stressed conditions.

  2. Polymer performance in cooling water: The influence of process variables

    SciTech Connect

    Amjad, Z.; Pugh, J.; Zibrida, J.; Zuhl, B.

    1996-12-01

    The key to the efficacy of phosphate and phosphonates in stabilized phosphate and all-organic cooling water treatment (CWT) programs is the presence and performance of polymeric inhibitors/dispersants. The performance of polymeric additives used in CWT programs can be adversely impacted by the presence of iron, phosphonate, or cationic polymer and influenced by a variety of process variables including system pH and temperature. In this paper, the performance of several polymeric additives is evaluated under a variety of stressed conditions.

  3. Low-Thermal-Budget Photonic Processing of Highly Conductive Cu Interconnects Based on CuO Nanoinks: Potential for Flexible Printed Electronics.

    PubMed

    Rager, Matthew S; Aytug, Tolga; Veith, Gabriel M; Joshi, Pooran

    2016-01-27

    In the developing field of printed electronics, nanoparticle based inks such as CuO show great promise as a low-cost alternative to other metal-based counterparts (e.g., silver). In particular, CuO inks significantly eliminate the issue of particle oxidation before and during the sintering process that is prevalent in Cu-based formulations. We report here the scalable and low-thermal-budget photonic fabrication of Cu interconnects employing a roll-to-roll (R2R)-compatible pulse-thermal-processing (PTP) technique that enables phase reduction and subsequent sintering of ink-jet-printed CuO patterns onto flexible polymer templates. Detailed investigations of curing and sintering conditions were performed to understand the impact of PTP system conditions on the electrical performance of the Cu patterns. Specifically, the impact of energy and power of photonic pulses on print conductivity was systematically studied by varying the following key processing parameters: pulse intensity, duration, and sequence. Through optimization of such parameters, highly conductive prints were obtained in <1 s with resistivity values as low as 10 μΩ cm (corresponding to ∼17% of the International Annealed Copper Standard (IACS) conductivity) was achieved. It was also observed that the introduction of an initial ink-drying step in ambient atmosphere, after the printing and before sintering, leads to significant improvements in mechanical integrity and electrical performance of the printed Cu patterns. Moreover, the viability of CuO reactive inks, coupled with the PTP technology and pre-sintering ink-drying protocols, has also been demonstrated for the additive integration of a low-cost Cu temperature sensor onto a flexible polymer substrate. PMID:26720684

  4. Low thermal budget photonic processing of highly conductive Cu interconnects based on CuO nanoinks. Potential for flexible printed electronics

    SciTech Connect

    Rager, Matthew S.; Aytug, Tolga; Veith, Gabriel M.; Joshi, Pooran C.

    2015-12-31

    The developing field of printed electronics nanoparticle based inks such as CuO show great promise as a low-cost alternative to other metal-based counterparts (e.g., silver). In particular, CuO inks significantly eliminate the issue of particle oxidation, before and during the sintering process, that is prevalent in Cu-based formulations. We report here the scalable and low-thermal budget photonic fabrication of Cu interconnects employing a roll-to-roll compatible pulse-thermal-processing (PTP) technique that enables phase reduction and subsequent sintering of inkjet-printed CuO patterns onto flexible polymer templates. Detailed investigations of curing and sintering conditions were performed to understand the impact of PTP system conditions on the electrical performance of the Cu patterns. Specifically, the impact of energy and power of photonic pulses on print conductivity was systematically studied by varying the following key processing parameters: pulse intensity, duration and sequence. Through optimization of such parameters, highly conductive prints in < 1 s with resistivity values as low as 100 n m has been achieved. We also observed that the introduction of an initial ink-drying step in ambient atmosphere, after the printing and before sintering, leads to significant improvements in mechanical integrity and electrical performance of the printed Cu patterns. Moreover, the viability of CuO reactive inks, coupled with the PTP technology and pre ink-drying protocols, has also been demonstrated for the additive integration of a low-cost Cu temperature sensor onto a flexible polymer substrate.

  5. Low thermal budget photonic processing of highly conductive Cu interconnects based on CuO nanoinks. Potential for flexible printed electronics

    DOE PAGESBeta

    Rager, Matthew S.; Aytug, Tolga; Veith, Gabriel M.; Joshi, Pooran C.

    2015-12-31

    The developing field of printed electronics nanoparticle based inks such as CuO show great promise as a low-cost alternative to other metal-based counterparts (e.g., silver). In particular, CuO inks significantly eliminate the issue of particle oxidation, before and during the sintering process, that is prevalent in Cu-based formulations. We report here the scalable and low-thermal budget photonic fabrication of Cu interconnects employing a roll-to-roll compatible pulse-thermal-processing (PTP) technique that enables phase reduction and subsequent sintering of inkjet-printed CuO patterns onto flexible polymer templates. Detailed investigations of curing and sintering conditions were performed to understand the impact of PTP system conditionsmore » on the electrical performance of the Cu patterns. Specifically, the impact of energy and power of photonic pulses on print conductivity was systematically studied by varying the following key processing parameters: pulse intensity, duration and sequence. Through optimization of such parameters, highly conductive prints in < 1 s with resistivity values as low as 100 n m has been achieved. We also observed that the introduction of an initial ink-drying step in ambient atmosphere, after the printing and before sintering, leads to significant improvements in mechanical integrity and electrical performance of the printed Cu patterns. Moreover, the viability of CuO reactive inks, coupled with the PTP technology and pre ink-drying protocols, has also been demonstrated for the additive integration of a low-cost Cu temperature sensor onto a flexible polymer substrate.« less

  6. Process for preparing tapes from thermoplastic polymers and carbon fibers

    NASA Technical Reports Server (NTRS)

    Chung, Tai-Shung (Inventor); Furst, Howard (Inventor); Gurion, Zev (Inventor); McMahon, Paul E. (Inventor); Orwoll, Richard D. (Inventor); Palangio, Daniel (Inventor)

    1986-01-01

    The instant invention involves a process for use in preparing tapes or rovings, which are formed from a thermoplastic material used to impregnate longitudinally extended bundles of carbon fibers. The process involves the steps of (a) gas spreading a tow of carbon fibers; (b) feeding the spread tow into a crosshead die; (c) impregnating the tow in the die with a thermoplastic polymer; (d) withdrawing the impregnated tow from the die; and (e) gas cooling the impregnated tow with a jet of air. The crosshead die useful in the instant invention includes a horizontally extended, carbon fiber bundle inlet channel, means for providing melted polymer under pressure to the die, means for dividing the polymeric material flowing into the die into an upper flow channel and a lower flow channel disposed above and below the moving carbon fiber bundle, means for applying the thermoplastic material from both the upper and lower channels to the fiber bundle, and means for withdrawing the resulting tape from the die.

  7. Polymer Solidification and Stabilization: Adaptable Processes for Atypical Wastes

    SciTech Connect

    Jensen, C.

    2007-07-01

    Vinyl Ester Styrene (VES) and Advanced Polymer Solidification (APS{sup TM}) processes are used to solidify, stabilize, and immobilize radioactive, pyrophoric and hazardous wastes at US Department of Energy (DOE) and Department of Defense (DOD) sites, and commercial nuclear facilities. A wide range of projects have been accomplished, including in situ immobilization of ion exchange resin and carbon filter media in decommissioned submarines; underwater solidification of zirconium and hafnium machining swarf; solidification of uranium chips; impregnation of depth filters; immobilization of mercury, lead and other hazardous wastes (including paint chips and blasting media); and in situ solidification of submerged demineralizers. Discussion of the adaptability of the VES and APS{sup TM} processes is timely, given the decommissioning work at government sites, and efforts by commercial nuclear plants to reduce inventories of one-of-a-kind wastes. The VES and APS{sup TM} media and processes are highly adaptable to a wide range of waste forms, including liquids, slurries, bead and granular media; as well as metal fines, particles and larger pieces. With the ability to solidify/stabilize liquid wastes using high-speed mixing; wet sludges and solids by low-speed mixing; or bead and granular materials through in situ processing, these polymer will produce a stable, rock-hard product that has the ability to sequester many hazardous waste components and create Class B and C stabilized waste forms for disposal. Technical assessment and approval of these solidification processes and final waste forms have been greatly simplified by exhaustive waste form testing, as well as multiple NRC and CRCPD waste form approvals. (authors)

  8. Full-solution processed flexible organic solar cells using low-cost printable copper electrodes.

    PubMed

    Li, Kan; Zhen, Hongyu; Niu, Liyong; Fang, Xu; Zhang, Yaokang; Guo, Ruisheng; Yu, You; Yan, Feng; Li, Haifeng; Zheng, Zijian

    2014-11-12

    Full-solution-processed flexible organic solar cells (OSCs) are fabricated using low-cost and high-quality printable Cu electrodes, which achieve a power conversion efficiency as high as 2.77% and show remarkable stability upon 1000 bending cycles. This device performance is thought to be the best among all full-solution-processed OSCs reported in the literature using the same active materials. This printed Cu electrode is promising for application in roll-to-roll fabrication of flexible OSCs. PMID:25220216

  9. Expected and unexpected achievements and trends in radiation processing of polymers

    NASA Astrophysics Data System (ADS)

    Czvikovszky, T.

    2003-06-01

    The last four decades produced exponential development in the polymer processing. Radiation processing—initiated also about 40 years ago—yielded a similar pathway of development in the beginning, mostly in the radiation crosslinking of polymers and in the radiation sterilization of polymer products. There are some unexpected results in the developments of the radiation chemistry of polymers utilized well in the polymer processing today. The most dynamical developments of the microelectronics in our days are based on the efficient utilization of radiation-crosslinkable negative photoresist polymers and the radiation degradable positive photoresist polymers. Rapid prototyping and rapid tooling are indispensable methods in the continuously renewing manufacturing technologies of metal and plastic parts for almost all the industrial branches. Polymer composite manufacturing is also profited in many ways from the experiences of radiation technology. Compatibilization through radiation-reactive monomers and oligomers is attacking two great fields of the future polymer processing. Recycling of commingled polymer wastes, and manufacturing new type of alloys of different synthetic as well as natural polymers are requiring well-engineered interface, which can be achieved by radiation processing in a technically feasible and economically viable way.

  10. Polymer processing by a low energy ion accelerator

    NASA Astrophysics Data System (ADS)

    Lorusso, A.; Velardi, L.; Nassisi, V.; Paladini, F.; Visco, A. M.; Campo, N.; Torrisi, L.; Margarone, D.; Giuffrida, L.; Rainò, A.

    2008-05-01

    Ion implantation is a process in which ions are accelerated toward a substrate at energies high enough to bury them just below the surface substrate in order to modify the surface characteristics. Laser-produced plasma is a very suitable and low cost technique in the production of ion sources. In this work, a laser ion source is developed by a UV pulsed laser of about 108 W/cm2 power density, employing a C target and a post ion acceleration of 40 kV to increase the ion energy. In this work, we implanted C ions on ultra-high-molecular-weight-polyethylene (UHMWPE) and low-density polyethylene (LDPE). We present the preliminary results of surface property modifications for both samples. In particular, we have studied the modifications of the surface micro-hardness of the polymers by applying the "scratch test" method as well as the hydrophilicity modifications by the contact angle measurements.