Skip to main content
SpringerLink
Log in

Improvement of cross-machine directional thickness deviation for uniform pressure-sensitive adhesive layer in roll-to-roll slot-die coating process

  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

In this study, a roll-to-roll (R2R) slot-die coating process for producing pressure-sensitive adhesive (PSA) layers was developed. PSAs are used for display applications and the production of various types of films based on lamination processes. The slot-die coating process has been adapted to uniform large-area deposition. However, in actual adhesive coating using a large-area R2R system, a cross machine directional difference in coated thickness is observed. Based on a previous study, the coating speed and coating gap were selected as the main controllable coating parameters that influence the adhesive layer thickness. An experimental study was performed to optimize the coating condition. By using statistical and mathematical approaches, an excellent coating layer was obtained with 50-nm roughness, 5-μm thickness, and 1.6-μm waviness at a high coating speed of 10 m/min and coating gap of 300 µm. The proposed process logic and guideline could be applied to mass production in the industry.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Nam, I., Ha, K., Lee, K., Kim, L. J., Kim, M., et al., “Novel Versatile Pressure-Sensitive Adhesives for Polarizing Film of TFT-LCDs: Viscoelastic Characteristics and Light Leakage Performance,” International Journal of Adhesion and Adhesives, Vol. 31, No. 7, pp. 708–714, 2011.

    Article  Google Scholar 

  2. Hösel, M., Søndergaard, R. R., Jørgensen, M., and Krebs, F. C., “Comparison of UVCuring, Hotmelt, and Pressure Sensitive Adhesive as Roll-to-Roll Encapsulation Methods for Polymer Solar Cells,” Advanced Engineering Materials, Vol. 15, No. 11, pp. 1068–1075, 2013.

    Article  Google Scholar 

  3. Krebs, F. C., Tromholt, T., and Jørgensen, M., “Upscaling of Polymer Solar Cell Fabrication using Full Roll-to-Roll Processing,” Nanoscale, Vol. 2, No. 6, pp. 873–886, 2010.

    Article  Google Scholar 

  4. Krebs, F. C., Fyenbo, J., and Jørgensen, M., “Product integration of Compact Roll-to-Roll Processed Polymer Solar Cell Modules: Methods and Manufacture using Flexographic Printing, Slot-Die Coating and Rotary Screen Printing,” Journal of Materials Chemistry, Vol. 20, No. 41, pp. 8994–9001, 2010.

    Article  Google Scholar 

  5. Krebs, F. C., “All Solution Roll-to-Roll Processed Polymer Solar Cells Free From Indium-Tin-Oxide and Vacuum Coating Steps,” Organic Electronics, Vol. 10, No. 5, pp. 761–768, 2009.

    Article  Google Scholar 

  6. Søndergaard, R. R., Hösel, M., and Krebs, F. C., “Roll-to-Roll Fabrication of Large Area Functional Organic Materials,” Journal of Polymer Science Part B: Polymer Physics, Vol. 51, No. 1, pp. 16–34, 2013.

    Article  Google Scholar 

  7. Park, Y. J., Lim, D. H., Kim, H. J., Park, D. S., and Sung, I. K., “UVand Thermal-Curing Behaviors of Dual-Curable Adhesives based on Epoxy Acrylate Oligomers,” International Journal of Adhesion and Adhesives, Vol. 29, No. 7, pp. 710–717, 2009.

    Article  Google Scholar 

  8. Miyamoto, M., Ohta, A., Kawata, Y., and Nakabayashi, M., “Control of Refractive Index of Pressure-Sensitive Adhesives for the Optimization of Multilayered Media,” Japanese Journal of Applied Physics, Vol. 46, No. 6S, pp. 3978–3980, 2007.

    Article  Google Scholar 

  9. Chang, Y. R., Chang, H. M., Lin, C. F., Liu, T. J., and Wu, P. Y., “Three Minimum Wet Thickness Regions of Slot Die Coating,” Journal of Colloid and Interface Science, Vol. 308, No. 1, pp. 222–230, 2007.

    Article  Google Scholar 

  10. Carvalho, M. S. and Kheshgi, H. S., “Low Flow Limit in Slot Coating: Theory and Experiments,” AIChE Journal, Vol. 46, No. 10, pp. 1907–1917, 2000.

    Article  Google Scholar 

  11. Kang, H., Park, J., and Shin, K., “Statistical Analysis for the Manufacturing of Multi-Strip Patterns by Roll-to-Roll Single Slot-Die Systems,” Robotics and Computer-Integrated Manufacturing, Vol. 30, No. 4, pp. 363–368, 2014.

    Article  Google Scholar 

  12. Park, J., Shin, K., and Lee, C., “Optimized Design for Anti-Reflection Coating Process in Roll-to-Roll Slot-Die Coating System,” Robotics and Computer-Integrated Manufacturing, Vol. 30, No. 5, pp. 432–441, 2014.

    Article  Google Scholar 

  13. Chu, W. B., Yang, J. W., Wang, Y. C., Liu, T. J., Tiu, C., and Guo, J., “The Effect of Inorganic Particles on Slot Die Coating of Poly (Vinyl Alcohol) Solutions,” Journal of Colloid and Interface Science, Vol. 297, No. 1, pp. 215–225, 2006.

    Article  Google Scholar 

  14. Romero, O. J., Scriven, L., and Carvalho, M. S., “Effect of Curvature of Coating Die Edges on the Pinning of Contact Line,” AIChE Journal, Vol. 52, No. 2, pp. 447–455, 2006.

    Article  Google Scholar 

  15. Bhamidipati, K. L., Didari, S., Bedell, P., and Harris, T. A., “Wetting Phenomena during Processing of High-Viscosity Shear-Thinning Fluid,” Journal of Non-Newtonian Fluid Mechanics, Vol. 166, No. 12, pp. 723–733, 2011.

    Article  MATH  Google Scholar 

  16. Soltman, D. and Subramanian, V., “Inkjet-Printed Line Morphologies and Temperature Control of the Coffee Ring Effect,” Langmuir, Vol. 24, No. 5, pp. 2224–2231, 2008.

    Article  Google Scholar 

  17. Chesterfield, R., Johnson, A., Lang, C., Stainer, M., and Ziebarth, J., “Solution-Coating Technology for AMOLED Displays,” Information Display, Vol. 1, No. 11, pp. 24–30, 2011.

    Google Scholar 

  18. Braatz, R. D., Tyler, M. L., Morari, M., Pranckh, F. R., and Sartor, L., “Identification and Cross Directional Control of Coating Processes,” AIChE Journal, Vol. 38, No. 9, pp. 1329–1339, 1992.

    Article  Google Scholar 

  19. Lee, K. Y., Liu, L. D., and Ta-Jo, L., “Minimum Wet Thickness in Extrusion Slot Coating,” Chemical Engineering Science, Vol. 47, No. 7, pp. 1703–1713, 1992.

    Article  Google Scholar 

  20. DeGarmo, E. P., Black, J. T., and Kohser, R. A., “Degarmo’s Materials and Processes in Manufacturing,” John Wiley & Sons, pp. 65–92, 2011.

    Google Scholar 

  21. Lee, C., Kang, H., Kim, C., and Shin, K., “A Novel Method to Guarantee the Specified Thickness and Surface Roughness of the Roll-to-Roll Printed Patterns using the Tension of a Moving Substrate,” Journal of Microelectromechanical Systems, Vol. 19, No. 5, pp. 1243–1253, 2010.

    Article  Google Scholar 

  22. Yunker, P. J., Still, T., Lohr, M. A., and Yodh, A., “Suppression of the Coffee-Ring Effect by Shape-Dependent Capillary Interactions,” Nature, Vol. 476, No. 7360, pp. 308–311, 2011.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Design and Production Engineering, Konkuk University, 120, Neungdong-ro, Gwangjin-gu, Seoul, 143-701, South Korea

    Janghoon Park & Keehyun Shin

  2. School of Mechanical Engineering, Changwon National University, 20, Changwondaehak-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, 641-773, South Korea

    Changwoo Lee

Authors
  1. Janghoon Park
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Keehyun Shin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Changwoo Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Changwoo Lee.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Park, J., Shin, K. & Lee, C. Improvement of cross-machine directional thickness deviation for uniform pressure-sensitive adhesive layer in roll-to-roll slot-die coating process. Int. J. Precis. Eng. Manuf. 16, 937–943 (2015). https://doi.org/10.1007/s12541-015-0122-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-015-0122-1

Keywords

Search

Navigation