The manufacture of printed electronics by roll-to-roll printing machine requires more accurate register performance than conventional media printing technology. Moreover, high drying temperature and long drying time to sinter the inks can induce the substantial changes in the length of the substrate and consequently register errors. Among the roll-to-roll printing methods, the gravure one, despite its relatively fast productivity and fine-line printing capacity, has difficulty in achieving the required register specifications for printed electronics because of the dependence of the register control on web dynamics. This study proposes a roll-to-roll gravure-offset printing equipment, including the register measurement system designed to enhance register performance and the related register control method for the application of printed electronics. Each cylinder constituting the printing unit is driven independently by an individual servomotor. Moreover, the printing patterns of the plate cylinder can move in the axial direction by position control, as well as in the web transport direction by a phase shift of the plate cylinder, without affecting the dynamics of the web. The time difference between the measurement and the actual control action is considered and modeled. The register measurement system, including selections of sensors and marks is also proposed to consider the effect of the time difference. The simulation results and the experiments of the register control are shown to verify the effect of the time difference on the control performances. It is found that a proper estimation of time difference should be obtained in order to guarantee more accurate and stable control performances.
Measuring nonuniform web tension for roll-to-roll manufacturing of flexible and printed electronics
