Search Results (17)

Sensor miniaturization offers significant advantages, including enhanced SoC integration efficiency, reduced cost, and lightweight design. While the roll-to-roll printed electronics fabrication process is advantageous for the mass production of sensors compared to the traditional MEMS technology, producing sensors that require air gap-based 3D structures remains challenging. This study proposes an integration of roll-to-roll gravure printing with a transferring and bonding method for touch sensor fabrication. Unlike previously reported methods for sacrificial layer removal, this approach prevents stiction issues, thus enabling sensor miniaturization and providing the flexibility to select materials that minimize sensitivity degradation during scaling. For the lower part of the sensor, Ag and BaSO₄ were roll-to-roll gravure-printed on a flexible PET substrate to form the bottom electrode and dielectric layer, followed by BaSO₄ spin coating on the sensor’s anchor area to form a spacer. For the upper part, a water-soluble PVP sacrificial layer was roll-to-roll gravure-printed on another flexible PET substrate, followed by spin coating Ag and SU-8 to form the top electrode and the structural layer, respectively. The sacrificial layer of the upper part was removed with water to delaminate the top electrode and structural layer from the substrate, then transferred and bonded onto the spacer of the lower part. Touch sensors of three different sizes were fabricated, and their performances were comparatively analyzed along with that of an epoxy resin-based sensor, demonstrating that our sensor attained miniaturization while achieving relatively high sensitivity. Full article

The tension system is one of the most critical systems in gravure printed electronic equipment. It possesses a complex structure that spans the entire feeding process, from unwinding through printing to rewinding. This article focuses on the research of multi-span tension control for printing systems. Firstly, the characteristics and requirements of the tension-control system in the printing section were analyzed, and a multi-span tension-control structure was devised. Then, based on the coupled mathematical model of the multi-span tension system, a static decoupling model was formulated, and a first-order active disturbance rejection control (ADRC) controller was designed utilizing active disturbance rejection control technology. Finally, to verify the control performance of the ADRC decoupling controller for the printing tension system, simulation and experimental studies were conducted using MATLAB/Simulink R2018a and a dedicated experimental platform, and the results were then compared with those obtained from a traditional PID controller. The research findings indicate that the designed multi-span tension-control system demonstrates outstanding decoupling performance and anti-interference capabilities, effectively enhancing the tension-control accuracy of gravure printed electronic equipment. Full article

To improve the performance of the tension control system in gravure printed electronic equipment, it is necessary to study the tension system model of gravure-printing electronic equipment. This paper focuses on the coupling characteristics of multi-span tension systems. Firstly, based on the single-span tension model, the mathematical model of the printing tension subsystem is established and simplified into a general multi-span tension coupling model. Then, using the relationship between the inputs and outputs of the system, the coupling model is simulated using MATLAB/Simulink and verified through experiments on the gravure printed electronic platform. Finally, the coupling relationship and influence laws among multi-physical quantities of the system are analyzed. The research results show that changes in the input web tension of the multi-span system will affect the steady-state tension values of all subsequent spans. Moreover, the speed change in a roller in the multi-span system will not only affect the steady-state tension value of its own span, but also cause transient tension fluctuations in all subsequent spans. The findings of this paper provide an important theoretical basis for the research of the tension system in gravure printed electronic equipment, contributing to the enhancement of printed electronic product quality. Full article

Interest in printed batteries is growing due to their applications in our daily lives, e.g., for portable and wearable electronics, biomedicals, and internet of things (IoT). The main advantages offered by printing technologies are flexibility, customizability, easy production, large area, and high scalability. Among the printing techniques, gravure is the most appealing for the industrial manufacture of functional layers thanks to its characteristics of high quality and high speed. To date, despite its advantages, such technology has been little investigated, especially in the field of energy since it is difficult to obtain functionality and adequate mass loading using diluted inks. In this review, the recent results for printed lithium-ion batteries are reported and discussed. A methodology for controlling the ink formulation and process based on the capillary number was proposed to obtain high printing quality and layer functionality. Specific concerns were found to play a fundamental role for each specific material and its performance when used as a film. Considering all such issues, gravure can provide high performance layers. A multilayer approach enables the desired layer mass loading to be achieved with advantages in terms of bulk homogeneity. Such results can boost the future industrial employment of gravure printing in the field of printed batteries. Full article

In recent years, researchers prepared composite conductive inks with high conductivity, high thermal conductivity, strong stability, and excellent comprehensive mechanical properties by combining carbon-based materials such as graphene and carbon nanotubes with metal-based materials. Through new electronic printing technologies, conductive inks can be used not only to promote the development of integrated circuits but also in various new electronic products. The conductive mechanism and the main types of conductive inks are introduced in this review. The advantages of electronic printing technology for preparing integrated circuits are analyzed. The research progress of fabricating integrated circuits with different electronic printing processes, such as screen printing, gravure printing, flexographic printing, and inkjet printing, are summarized. The development trend of carbon-based composite conductive ink for integrated circuits is prospected. Full article

Roll-to-roll gravure (R2Rg) has become highly affiliated with printed electronics in the past few years due to its high yield of printed thin-film transistor (TFT) in active matrix devices, and to its low cost. For printing TFTs with multilayer structures, achieving a high-precision in overlay printing registration accuracy (OPRA) is a key challenge to attain the high degree of TFT integration through R2Rg. To address this challenge efficiently, a digital twin paradigm was first introduced in the R2Rg system with an aim to optimize the OPRA by developing a predictive model based on typical input variables such as web tension, nip force, and printing speed in the R2Rg system. In our introductory-level digital twin, errors in the OPRA were collected with the variable parameters of web tensions, nip forces, and printing speeds from several R2Rg printing processes. Subsequently, statistical features were extracted from the input data followed by the training of a deep learning long-short term memory (LSTM) model for predicting machine directional error (MD) in the OPRA. As a result of training the LSTM model in our digital twin, its attained accuracy of prediction was 77%. Based on this result, we studied the relationship between the nip forces and printing speeds to predict the MD error in the OPRA. The results indicated a correlation between the MD error in the OPRA and the printing speed, as the MD error amplitude in the OPRA tended to decline at the higher printing speed. Full article

Graphene/metal nanocomposites have shown a strong potential for use in electronic applications. In particular, the combination of silver nanowires (AgNWs) with graphene derivatives leads to the formation of an efficient conductive network, thus improving the electrical properties of a composite. This work focused on developing highly conductive hydrophilic hybrids of simultaneously functionalized and reduced graphene oxide (f-rGO) and AgNWs in different weight ratios by following two different synthetic routes: (a) the physical mixture of f-rGO and AgNWs, and (b) the in situ reduction of GO in the presence of AgNWs. In addition, the role of AgNWs in improving the electrical properties of graphene derivatives was further examined by mixing AgNWs with a hybrid of few-layered graphene with functionalized multiwalled carbon nanotubes (FLG/MWNT-f-OH). The studied materials showed a remarkable improvement in the overall electrical conductivity due to the synergistic effect of their components, which was proportional to the percentage of Ag and dependent on the procedure of the hybrid formation. One of the f-rGO/AgNWs composites was also selected for the preparation of gravure printing inks that were tested to determine their rheological and printing properties. All of the f-rGO/AgNWs composites were shown to be very promising materials for use as conductive inks for flexible electronics. Full article

It is a common practice to add rheology modifiers to functional inks, such as graphene inks, to optimize the rheological properties so that they can be printed with a certain printing technique. This practice may lead to inks formulations with poorer electrical, optical, and mechanical performance upon its application, which are of paramount importance in printed electronics. In this study, we demonstrate for three different commercial graphene-based inks that it is possible to control the amount of ink transferred to the flat surface by tweaking printing parameters, such as the velocity and the length scale of the gravure cell, without modifying the rheology of the ink. Finally, the results are summarized in printing maps based on dimensionless numbers, namely, the capillary and Reynolds numbers. Full article

Gravure printing, which is a roll-to-roll printed electronics system suitable for high-speed patterning of functional layers have advantages of being applied to flexible webs in large areas. As each of the printing procedure from inking to doctoring followed by ink transferring and setting influences the quality of the pattern geometry, it is necessary to detect and diagnose factors causing the printing defects beforehand. Data acquisition with three triaxial acceleration sensors for fault diagnosis of four major defects such as doctor blade tilting fault was obtained. To improve the diagnosis performances, optimal sensor selection with Sensor Data Efficiency Evaluation, sensitivity evaluation for axis selection with Directional Nature of Fault and feature variable optimization with Feature Combination Matrix method was applied on the raw data to form a Smart Data. Each phase carried out on the raw data progressively enhanced the diagnosis results in contents of accuracy, positive predictive value, diagnosis processing time, and data capacity. In the case of doctor blade tilting fault, the diagnosis accuracy increased from 48% to 97% with decreasing processing time of 3640 s to 16 s and the data capacity of 100 Mb to 5 Mb depending on the input data between raw data and Smart Data. Full article

Zinc oxide (ZnO) nanowires (NWs) are excellent candidates for the fabrication of energy harvesters, mechanical sensors, and piezotronic and piezophototronic devices. In order to integrate ZnO NWs into flexible devices, low-temperature fabrication methods are required that do not damage the plastic substrate. To date, the deposition of patterned ceramic thin films on flexible substrates is a difficult task to perform under vacuum-free conditions. Printing methods to deposit functional thin films offer many advantages, such as a low cost, low temperature, high throughput, and patterning at the same stage of deposition. Among printing techniques, gravure-based techniques are among the most attractive due to their ability to produce high quality results at high speeds and perform deposition over a large area. In this paper, we explore gravure printing as a cost-effective high-quality method to deposit thin ZnO seed layers on flexible polymer substrates. For the first time, we show that by following a chemical bath deposition (CBD) process, ZnO nanowires may be grown over gravure-printed ZnO nanoparticle seed layers. Piezo-response force microscopy (PFM) reveals the presence of a homogeneous distribution of Zn-polar domains in the NWs, and, by use of the data, the piezoelectric coefficient is estimated to be close to 4 pm/V. The overall results demonstrate that gravure printing is an appropriate method to deposit seed layers at a low temperature and to undertake the direct fabrication of flexible piezoelectric transducers that are based on ZnO nanowires. This work opens the possibility of manufacturing completely vacuum-free solution-based flexible piezoelectric devices. Full article

Nowadays, flexible transparent conductive film (FTCF) is one of the important components of many flexible electronic devices. Due to comprehensive performances on optoelectronics, FTCF based on silver nanowires (AgNWs) networks have received great attention and are expected to be a new generation of transparent conductive film materials. Due to its simple process, printed electronic technology is now an important technology for the rapid production of low-cost and high-quality flexible electronic devices. AgNWs-based FTCF fabricated by using printed electronic technology is considered to be the most promising process. Here, the preparation and performance of AgNW ink are introduced. The current printing technologies are described, including gravure printing, screen printing and inkjet printing. In addition, the latest methods to improve the conductivity, adhesion, and stability of AgNWs-based FTCF are introduced. Finally, the applications of AgNWs-based FTCF in solar cells, transparent film heaters, optoelectronic devices, touch panel, and sensors are introduced in detail. Therefore, combining various printing technologies with AgNWs ink may provide more opportunities for the development of flexible electronic devices in the future. Full article

The preservation of perishable products to maintain their quality is of paramount importance for food safety and security, and is attracting more attention due to increasing concerns regarding food quality, healthcare, and quality of life. Advances in technology and materials in recent years have led to the development and implementation of intelligent packaging for perishable products that can monitor or even control their quality in a supply chain. In this paper, the techniques used in intelligent packaging (i.e., indicators, sensors, and identification technology) and the major printing methods for fabricating electronics (i.e., inkjet printing, screen printing, and gravure printing) are reviewed with a focus on the packaging of perishable products. Although the high manufacturing costs pose a major challenge the commercialization and large-scale deployment of perishable products, it is expected that the technological progresses in printing electronics will significantly reduce the manufacturing cost of intelligent packaging to a threshold of acceptance by markets. In addition, the broad applications of intelligent packaging can facilitate the traction and monitoring of perishable products for better control of the product quality and improved management of the supply chain. Full article

Printed batteries have undergone increased investigation in recent years because of the growing daily use of small electronic devices. With this in mind, industrial gravure printing has emerged as a suitable production technology due to its high speed and quality, and its capability to produce any shape of image. The technique is one of the most appealing for the production of functional layers for many different purposes, but it has not been highly investigated. In this study, we propose a LiFePO₄ (LFP)-based gravure printed cathode for lithium-ion rechargeable printed batteries and investigate the possibility of employing this printing technique in battery manufacture. Full article

Although printed electronics technology has been recently employed in the production of various devices, its use for the fabrication of electronic devices with air-gap structures remains challenging. This paper presents a productive roll-to-roll printed electronics method for the fabrication of capacitive touch sensors with air-gap structures. Each layer of the sensor was fabricated by printing or coating. The bottom electrode, and the dielectric and sacrificial layers were roll-to-roll slot-die coated on a flexible substrate. The top electrode was formed by roll-to-roll gravure printing, while the structural layer was formed by spin-coating. In particular, the sacrificial layer was coated with polyvinyl alcohol (PVA) and removed in water to form an air-gap. The successful formation of the air-gap was verified by field emission scanning electron microscopy (FE-SEM). Electrical characteristics of the air-gap touch sensor samples were analyzed in terms of sensitivity, hysteresis, and repeatability. Experimental results showed that the proposed method can be suitable for the fabrication of air-gap sensors by using the roll-to-roll printed electronics technology. Full article

In this study, an organic–inorganic (O–I) nanohybrid obtained by incorporating an alkoxysilane-functionalized amphiphilic polymer precursor into a SiO₂–TiO₂ hybrid network was successfully utilized as a buffer layer to fabricate a flexible, transparent, and stable conductive substrate for solution-processed silver nanowires (AgNWs) and graphene under ambient conditions. The resulting O–I nanohybrid sol (denoted as AGPTi) provided a transmittance of the spin-coated AgNWs on an AGPTi-coated glass of 99.4% and high adhesion strength after a 3M tape test, with no visible changes in the AgNWs. In addition, AGPTi acted as a highly functional buffer layer, absorbing the applied pressure between the conductive materials, AgNWs and graphene, and rigid substrate, leading to a significant reduction in sheet resistance. Furthermore, gravure-printed AgNWs and graphene on the AGPTi-based flexible substrate had uniform line widths of 490 ± 15 and 470 ± 12 µm, with 1000-cycle bending durabilities, respectively. Full article