Tejasvi Parupudi

Dec 8, 2015

PhD student, ZBML

Birck Nanotechnology Center

sparupud@purdue.edu

ROLL TO ROLL (R2R)

PRINTING OF

FUNCTIONAL NANODEVICES

IE 590

NEED FOR R2R PRINTING

STATUS QUO OF R2R TECHNOLOGY

TECHNIQUES FOR MATERIAL DEPOSITION

NANODEVICES BASED ON NTS AND NWS

CASE STUDY: GRAPHENE BASED DEVICES

DESIGN FLOW FOR SPECIFIC APPLICATION

CONTENTS

WHAT IS SCALABLE NANOMANUFACTURING

Nanomanufacturing Platforms

•Roll-to-Roll Process

•Inkjet Printing

Current NEED exists in developing R2R compatible:

•Materials

•Processes

•Applications

Desired OUTCOMES

• Fabrication of hybrid functional electronic and photonic devices

•Fabrication of solar cells (energy harvesting)

•Fabrication of biomedical devices

https://www.nsf.gov/funding/pgm_summ.jsp?pims_id=13347

“NANOMANUFACTURING IS THE PRODUCTION OF USEFUL NANO-SCALE MATERIALS,

STRUCTURES, DEVICES AND SYSTEMS IN AN ECONOMICALLY VIABLE MANNER”

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Flexible electronics (multi-device multi-functional) system-on-film

Cooper, K. P., & Wachter, R. F. (2012, October). High-rate, roll-to-roll nanomanufacturing of flexible systems. In SPIE NanoScience+ Engineering (pp. 846602-846602). International Society for Optics and Photonics.

Technology needs

WHAT IS R2R“COATING AND PRINTING TECHNIQUES THAT WERE DEVELOPED DUE TO THE NEED TO SCALE UP

MANUFACTURING AT LOW COST FOR LARGE SCALE DEPLOYMENT ON FLEXIBLE SUBSTRATES

EARN THE NAME ROLL-TO-ROLL”

Process mechanisms •Material Deposition

•Patterning

•Laminating and Sealing

Advantages•High production rates and yields

•Reduced cost of manufacturing

•Continuous production of mass quantities

http://energy.gov/sites/prod/files/2015/02/f19/QTR%20Ch8%20-%20Roll%20To%20Roll%20Processing%20TA%20Feb-13-2015.pdfKhan, S., et al. (2015). Technologies for Printing Sensors and Electronics over Large Flexible Substrates: A Review. Sensors Journal, IEEE, 15(6), 3164-3185.

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STATUS QUO OF R2R

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R2R Vacuum web coating1

1http://www.intelli-vation.com/roll-to-roll-thin-film-web-coating-tools/2Lee, M. H et al. (2011). Roll-to-roll anodization and etching of aluminum foils for high-throughput surface nanotexturing.Nano letters,11(8), 3425-3430.3Välimäki, M., et al. (2015). R2R-printed inverted OPV modules–towards arbitrary patterned designs. Nanoscale, 7(21), 9570-9580.

Surface nanotexturing of Aluminum foils2

OPV Modules by R2R3

Screen Printing Flexo printing

Inkjet printing

Spin Coating Spray Coating

Blade Coating Slot-die Coating Gravure printing/coating

COATING METHODS PRINTING METHODS

MATERIAL DEPOSITION

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Engraved cylinder roll cells (30R,90R,180R)

Slot-die coating head

MICROGRAVURE ROLL PRINTING SLOT DIE ROLL COATING

MIRWEC MATERIAL DEPOSITION

http://www.mirwecfilm.com/microgravure.php

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Moving Web

Ink Bath

20-50mm diameter

Metal cylinder with chrome-plated

coating

GRAVURE ROLL COATING

Slot containing ink

SLOT DIE ROLL COATING

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Parameter Slot Die Microgravure Inkjet

Viscosity (Pa.s) 0.001-25 0.001-2 0.001-0.03

Line speed Faster speed gives less thickness

Faster speed gives less thickness

Dependent on ink properties

Layer thickness control

Web speed and ink flow rate

Roller to web speed ratio, pattern and depth of roller cells

Number of droplets jetted

Applications Multilayer ceramic capacitors, Li-ion rechargeable battery electrodes, Polyimide coating for flexible printed circuits, polymer solar celllayers etc

Nano polymer films, 3D holograms, LCD displays etc

Active membrane layers, polymer inks, conductive inks, transparent electrode gels etc

COMPARISON OF PROCESSES

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INKS FOR R2R PROCESSES

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•Water-based inks: 100s of cP

•UV inks*: 1000-5000 cP

•PDMS: 850-1150 cP

• Viscosity

• Conductivity

• Wettability

• Packing density (particle size)

• UV polymerizable hydrogel

Eg: PEGDMA

• Biofunctional nanoparticles,

nanotubes

• Bacterial and viral cell

suspensions

• Temperature resistant cell

cultures

FEW TUNABLE PROPERTIES OF INKS VISCOSITY OF COMMON INK TYPES

BIOMATERIALS FOR R2R

Derby, B. (2010). Inkjet printing of functional and structural materials: fluid property requirements, feature stability, andresolution. Annual Review of Materials Research, 40, 395-414.

*http://www.rupainks.com/uv-inks.html

PRINTABLE INKJET INK SELECTION

WEB MATERIALS FOR R2R

Poly Ethylene Terephthalate (PET)Max. process temperature: 150C50µm thick, 180 mm wide

PolyEthylene Naphthalate (PEN)Max. process temperature: 180C

PolyImide (PI) or KaptonMax. process temperature: 350C

Biaxially Oriented PolyPropylene (BOPP)Max. Process Temperature: 100C

Poly Carbonate (PC)Max. Process Temperature: 150C

Parchment PaperMax. Process Temperature: 230C

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PRACTICAL ISSUES WITH R2R PRINTING

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1. LIMITED AMOUNT OF WEB MATERIALS

2. PROCESS REPEATABILITY

3. ACCURACY OF PRINTS

4. LACK OF STANDARDIZATION OF R2R PROCESS

SUGGESTIONS TO OVERCOME ISSUES :1. EXPLORE COMPOSITE MATERIALS (POLYMER + METAL) OR (POLYMER + CELLULOSE) TO

BENEFIT FROM BOTH PROPERTIES

2. RUN STATISTICAL DESIGN OF EXPERIMENTS ANALYSIS TO GET TRENDS FOR PROCESS

PARAMETERS

3. PRECISION STAMPS FOR REPLICATION

4. STANDARDIZATION OF “EQUIPMENT, MATERIALS, TESTING METHODS, AND THE EDUCATION OF

THIS TECHNOLOGY”1

1Hoffman, J., et al. (2013). The standardization of printable materials and direct writing systems. Journal of Electronic Packaging, 135(1), 011006.

PATTERNING

Lim, H., et al., (2014). Roll-to-roll nanoimprint lithography for patterning on a large-area substrate

roll. Microelectronic Engineering, 123, 18-22.

NANODEVICES FROM CNTS AND AG NWS

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MWCNT based IR Sensors1AgNW/ ZnO based ITO free transparent electrodes2

1John, J., et al. (2014). Suspended Multiwall Carbon Nanotube‐Based Infrared Sensors via Roll‐to‐Roll Fabrication. Advanced Optical Materials, 2(6), 581-587.2Angmo, D., et al. (2015). Roll‐to‐Roll Printed Silver Nanowire Semitransparent Electrodes for Fully Ambient Solution‐Processed Tandem Polymer Solar Cells. Advanced Functional Materials, 25(28), 4539-4547.3 Allen, M., et al. (2011). R2R gravure and inkjet printed RF resonant tag. Microelectronic engineering, 88(11), 3293-3299.

All R2R printed resonant RFID tag3

TRADITIONAL VS STATE-OF-ART NANODEVICE

FABRICATION TECHNIQUES

Transfer Printing: GrapheneAdvantage: Scalable

Bae, S. et al., Nat. Nanotechnology. 2010, 5, 574.

Patterning: He ion beam milling Advantage: Customizable

Case Study: Graphene

ROLL-TO-ROLL GRAPHENE DEVICES

Performance of monolayer graphene film :

Graphene based flexible touch-screen display(Graphene is used as transparent electrode)

DESIGN FLOW FOR FUNCTIONAL NANODEVICE FABRICATION :

SPECIFIC EXAMPLE

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Eg Application: In-situ Oxygen monitoring for wound healingDevice: Integrated nanoscale oxygen generator and sensor Process: Layer by layer assembled device

1. Suitable material selection (KMnO4 and H2O2)2. Suitable web selection (parchment paper) – requiring optimization of

temperature, chemical sensitivity3. Web processing (laser treatment) to render it hydrophilic for aq. phase reaction4. Patterned spots with catalyst for oxygen generation (Layer 1)5. Additional layer patterned with sensing material (Layer 2)6. Overlay registration of both layers7. Packaging

THANK YOU

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