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Polymers
Volume 15
Issue 11
10.3390/polym15112478
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Article

Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing

by
Hojin Jeon
1,
Jaehyun Noh
1,
Minho Jo
1,
Changbeom Joo
2,
Jeongdai Jo
3 and
Changwoo Lee
4,*
1
Department of Mechanical Design and Production Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of Korea
2
Department of Mechanical Engineering, Stevens Institute of Technology, 1 Castle Point Terrace, Hoboken, NJ 07030, USA
3
Department of Printed Electronics, Korea Institute of Machinery and Materials, 156, Gajeongbuk-ro, Yuseong-gu, Daejeon 34103, Republic of Korea
4
Department of Mechanical and Aerospace Engineering, Konkuk University, 120 Neungdong-ro, Gwangjin-gu, Seoul 05029, Republic of Korea
*
Author to whom correspondence should be addressed.
Polymers 2023, 15(11), 2478; https://doi.org/10.3390/polym15112478
Submission received: 1 May 2023 / Revised: 17 May 2023 / Accepted: 24 May 2023 / Published: 27 May 2023
(This article belongs to the Special Issue Polymers in Roll to Roll Processes)
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Abstract

A roll-to-roll manufacturing system performs printing and coating on webs to mass-produce large-area functional films. The functional film of a multilayered structure is composed of layers with different components for performance improvement. The roll-to-roll system is capable of controlling the geometries of the coating and printing layers using process variables. However, research on geometric control using process variables is limited to single-layer structures only. This study entails the development of a method to proactively control the geometry of the upper coated layer by using the lower-layer coating process variable in the manufacture of a double-coated layer. The correlation between the lower-layer coating process variable and upper coated layer geometry was examined by analyzing the lower-layer surface roughness and spreadability of the upper-layer coating ink. The correlation analysis results demonstrate that tension was the dominant variable in the upper coated layer surface roughness. Additionally, this study found that adjusting the process variable of the lower-layer coating in a double-layered coating process could improve the surface roughness of the upper coating layer by up to 14.9%.
Keywords: functional film; ink spreadability; layered structures; roll-to-roll; slot-die coating; surface roughness functional film; ink spreadability; layered structures; roll-to-roll; slot-die coating; surface roughness

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MDPI and ACS Style

Jeon, H.; Noh, J.; Jo, M.; Joo, C.; Jo, J.; Lee, C. Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing. Polymers 2023, 15, 2478. https://doi.org/10.3390/polym15112478

AMA Style

Jeon H, Noh J, Jo M, Joo C, Jo J, Lee C. Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing. Polymers. 2023; 15(11):2478. https://doi.org/10.3390/polym15112478

Chicago/Turabian Style

Jeon, Hojin, Jaehyun Noh, Minho Jo, Changbeom Joo, Jeongdai Jo, and Changwoo Lee. 2023. "Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing" Polymers 15, no. 11: 2478. https://doi.org/10.3390/polym15112478

APA Style

Jeon, H., Noh, J., Jo, M., Joo, C., Jo, J., & Lee, C. (2023). Layer-by-Layer Engineered Flexible Functional Film Fabrication with Spreadability Control in Roll-to-Roll Manufacturing. Polymers, 15(11), 2478. https://doi.org/10.3390/polym15112478

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