scholarly journals Back Injection Molding of Sub-Micron Scale Structures on Roll-to-Roll Extrusion Coated Films

Polymers ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1410
Author(s):  
Sijia Xie ◽  
Jerome Werder ◽  
Helmut Schift
Keyword(s):  
Injection Molding ◽  
Flexible Electronics ◽  
Polymer Melt ◽  
Surface Functionality ◽  
Roll To Roll ◽  
Scale Structures ◽  
Pet Film ◽  
Nanoparticle Ink ◽  
Carrier Film ◽  
Pet Films

Roll-to-roll extrusion coated films were bonded onto polymer parts by back injection molding (BIM). The polypropylene (PP) coated polyethylene terephthalate (PET) films were pre-patterned with microstructured V-shaped grooves with 3.2 µm and 53 µm width, and other geometries. Bonding on PET and poly(methyl methacrylate) (PMMA) parts was facilitated by either higher tool or melt temperatures but was particularly enhanced by applying a mild oxygen plasma to the backside of the PET film prior to injection of the polymer melt. Silver wires from conductive nanoparticle ink were embedded into the PP coating during the BIM process by controlled collapse of the V-grooves. Thus, the feasibility of combining standard carrier film materials for printed flexible electronics and packaging into a non-flat polymer part was demonstrated, which could be a helpful step towards the fabrication of polymer parts with surface functionality.

Fabrication of 3D Temperature Sensor Using Magnetostrictive Inkjet Printhead

2020 ◽  
Vol 64 (5) ◽  
pp. 50405-1-50405-5
Author(s):  
Young-Woo Park ◽  
Myounggyu Noh
Keyword(s):  
Flexible Electronics ◽  
Inkjet Printing ◽  
Temperature Sensor ◽  
Computer Aided Design ◽  
Low Cost ◽  
Three Dimensional ◽  
Drop On Demand ◽  
Aided Design ◽  
Nanoparticle Ink ◽  
Inkjet Printhead

Abstract Recently, the three-dimensional (3D) printing technique has attracted much attention for creating objects of arbitrary shape and manufacturing. For the first time, in this work, we present the fabrication of an inkjet printed low-cost 3D temperature sensor on a 3D-shaped thermoplastic substrate suitable for packaging, flexible electronics, and other printed applications. The design, fabrication, and testing of a 3D printed temperature sensor are presented. The sensor pattern is designed using a computer-aided design program and fabricated by drop-on-demand inkjet printing using a magnetostrictive inkjet printhead at room temperature. The sensor pattern is printed using commercially available conductive silver nanoparticle ink. A moving speed of 90 mm/min is chosen to print the sensor pattern. The inkjet printed temperature sensor is demonstrated, and it is characterized by good electrical properties, exhibiting good sensitivity and linearity. The results indicate that 3D inkjet printing technology may have great potential for applications in sensor fabrication.

Influence of Temperature and Relative Humidity on Perm-Selectivity of PET Packaging Film

2011 ◽  
Vol 295-297 ◽  
pp. 1206-1210
Author(s):  
Yan Feng Guo ◽  
Xian Ping Ma ◽  
Yu Yan ◽  
Yun Gang Fu
Keyword(s):  
Water Vapor ◽  
Relative Humidity ◽  
Experimental Studies ◽  
Thermodynamic Temperature ◽  
Packaging Film ◽  
Influence Of Temperature ◽  
Carbon Dioxide Gas ◽  
Pet Film ◽  
Pet Films ◽  
Temperature Water

The main feature of this article is the investigation on the influence of temperature, relative humidity, film thickness on permeability of PET packaging film, the analysis of perm-selectivity of the packaging films for oxygen gas and carbon dioxide gas, and the evaluation on experimental formulas of water vapor, O2 and CO2 gas permeating rates on the basis of gas molecular osmotic reaction kinetics and regression analysis. The comparison between experimental studies and calculation indicates that: (1) with increment of ambient temperature water vapor, O2 and CO2 permeating rate of PET films and PET/Al film also rise, and the logarithm of water vapor, O2 and CO2 gas permeating rates has linear relation with the reciprocal of thermodynamic temperature, and (2) the influence of relative humidity on water vapor permeating rate of PET film with thickness 12µm is the least, and that of PET film with thickness 20µm and PET/Al film with thickness 18µm is a little obvious. (3) The PET films hold remarkable perm-selectivity for O2 and CO2 gas, and CO2 gas permeating rate is about two times of O2 gas, yet O2 and CO2 gas permeating rates of PET/Al film are both very low and have small difference, so the PET/Al film has better barrier performance than the PET film.

OLED Manufacturing on Flexible Substrates Towards Roll-to-Roll

MRS Advances ◽  
2019 ◽  
Vol 4 (24) ◽  
pp. 1367-1375 ◽  
Author(s):  
Dongxiang Wang ◽  
Jacqueline Hauptmann ◽  
Christian May
Keyword(s):  
High Throughput ◽  
Present Status ◽  
Manufacturing Cost ◽  
Flexible Substrates ◽  
Large Area ◽  
Thin Glass ◽  
Production Capability ◽  
Roll To Roll ◽  
Pet Film

ABSTRACTLarge area lighting OLEDs manufactured in a Roll-to-Roll (R2R) fashion enable the well-longed production capability with considerably high throughput based on flexible substrates, hence largely reduced OLED manufacturing cost. This paper will outline the present status of R2R OLED fabrication on ultra-thin glass with the focus on transparent OLED devices and how to perform segmentation by printing of silver- and dielectric pastes. Ultra-thin glass (UTG) is laminated on a PET film to avoid fabrication interruptions when glass cracks occur during the Roll-to-Roll process. The R2R fabricated flexible OLEDs also show key-values comparable to conventional OLEDs fabricated on small rigid glass in lab-scale.

scholarly journals ADHESION OF PET/PSMA INTERFACES REINFORCED WITH PLASMA TREATMENT

2006 ◽  
Vol 13 (02n03) ◽  
pp. 265-271
Author(s):  
CHI-AN DAI ◽  
TAI-AN TSUI ◽  
YAO-YI CHENG
Keyword(s):  
Fracture Toughness ◽  
Plasma Treatment ◽  
Fracture Energy ◽  
Functional Groups ◽  
Surface Composition ◽  
Treatment Time ◽  
Bulk Material ◽  
Plasma Treatment Time ◽  
Pet Film ◽  
Pet Films

The interface between biaxially oriented poly (ethylene terephthalate) (PET) films and poly (styrene-co-maleic anhydride) (PSMA) was reinforced by nitrogen plasma treatment of PET film and subsequent annealing treatment of the PET/PSMA bi-material. The fracture toughness, Gc, of the interface was quantitatively measured using an asymmetric double cantilever beam test (ADCB). X-ray photoelectron spectrometry (XPS) was used to measure the change in the surface composition of PET films upon plasma treatment and correlate the fracture toughness of the interface. The fracture energy of PET/PSMA interface is significantly enhanced by annealing the plasma treated PET with PSMA at a temperature greater than the glass transition temperature of PSMA (~ 120°C). At an annealing temperature of 150°C, Gc increases with increasing plasma treatment time and reaches a plateau value of ~ 100–120 J/m2, a two order of magnitude increase in Gc compared with that of samples annealed at 130°C. The enhancement of the adhesion is resulted from the in-situ formation of copolymers due to reaction between amine functional groups from the plasma treatment and anhydride groups from PSMA. For plasma treatment time < 10 s, scanning electron microscope (SEM) measurement show that the fracture surface is relatively smooth indicating an interfacial failure between PET/PSMA. With increasing plasma treatment time and therefore increasing the amount of nitrogen functional groups on PET surface, large plastic deformation takes place at the PET/PSMA interface. For treatment time ≥ 100–150 s, the PET/PSMA interface becomes stronger than PET bulk material and consequently crack deviates from the interface and the failure occurs within the PET film. The interlayer fracture energy of a biaxially oriented PET film can thus be quantitatively measured with a Gc value of roughly 120 J/m2.

Rheological behavior of PS polymer melt under ultra high speed injection molding

2012 ◽  
Vol 31 (7) ◽  
pp. 864-869 ◽  
Author(s):  
Shia-Chung Chen ◽  
Won-Hsion Liao ◽  
Jung-Peng Yeh ◽  
Rean-Der Chien
Keyword(s):  
Injection Molding ◽  
Rheological Behavior ◽  
High Speed ◽  
Polymer Melt ◽  
Ultra High Speed

Flexible Magnetics: Magnetic Lithography and Fabrication of Magnetic Masks on Thin Plastic Substrates

2003 ◽  
Vol 769 ◽  
Author(s):  
Z. Z. Bandić ◽  
H. Xu ◽  
J.E.E. Baglin ◽  
T. R. Albrecht
Keyword(s):  
Magnetic Material ◽  
Flexible Electronics ◽  
Flexible Substrate ◽  
Magnetic Transition ◽  
Soft Magnetic Material ◽  
Plastic Substrate ◽  
Magnetic Media ◽  
Soft Magnetic ◽  
Plastic Substrates ◽  
Pet Films

AbstractFlexible magnetic lithography is a process qualitatively analogous to contact optical lithography which transfers information from a patterned magnetic mask (analog of optical photomask) to magnetic media (analog of photoresist), and is interesting for applications in instantaneous parallel magnetic recording. The magnetic mask consists of patterned soft magnetic material (FeNiCo, FeCo) on a flexible plastic substrate, typically Polyethylene Teraphtalate (PET). When uniformly magnetized media is brought into intimate contact with the magnetic mask, an externally applied magnetic field selectively changes the magnetic orientation in the areas not covered with the soft magnetic material. Flexible substrate of the magnetic mask o.ers superior compliance to magnetic media which is likely to have imperfect flatness and surface particulate contamination.Although magnetic in physical nature, flexible magnetics draws interesting parallels to flexible electronics, especially in challenges of fabrication of sub-micron patterns on thin flexible plastic substrates. We fabricated samples of sub-micron patterned FeCo and FeNiCo magnetic masks on PET substrates by using combined lamination/release process of PET films. Rigid substrates, typically silicon or quartz were initially laminated with PET films and processed using standard fabrication procedures. After completing magnetic mask device fabrication, PET films were released from the rigid substrates.We successfully transferred patterns from magnetic masks to hard disk CrPtCo-based magnetic media. The details of the method, including physics of the magnetic lithography pattern transfer, fabrication of the magnetic mask on flexible PET substrates, lamination and release of PET films, and magnetic force microscopy (MFM) images of the magnetic transition patterns are reported.

Development of Advanced Hybrid Polymer Melt Delivery Systems for Efficient High Precision Injection Molding

2020 ◽  
Vol 142 (7) ◽  
Author(s):  
Chandresh Thakur ◽  
Khalid Alqosaibi ◽  
Animesh Kundu ◽  
John P. Coulter
Keyword(s):  
Injection Molding ◽  
Polymer Melt ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Investigations ◽  
Liquid Crystal Polymers ◽  
Ansys Fluent ◽  
Engineering Plastics ◽  
Software Modules ◽  
Melt Manipulation ◽  
Butadiene Styrene

Abstract A novel melt manipulation “RheoDrop” concept for hot runner injection molding is presented. In this concept, a controlled rotational shear is applied to a polymer melt in the hot drop to reduce its viscosity without raising the temperature. This is achieved by providing a transient rotational motion to the valve pin in the hot drop. This strategy is developed to mitigate issues associated with cold slug formation during injection molding in hot runner systems. The cold slug formation is particularly relevant for injection molding of engineering plastics such as liquid crystal polymers (LCPs) for medical and electronic applications. Analytical and experimental investigations were performed to validate the concept. The efficacy of the concept is assessed analytically utilizing a combination of two software modules, autodesk, moldflow and ansys fluent. The results confirmed that the concept was able to produce enough shear to reduce the dynamic viscosity between injection molding cycles. A prototype RheoDrop system was designed and developed and retrofitted in a four drop hot runner system mold to experimentally validate the concept. Preliminary experiments were performed utilizing acrylonitrile butadiene styrene, and parts were successfully fabricated at temperatures that are too low for traditional molding in a hot runner system.

Evaluation of a Piezoelectric Energy Extraction Device for Cavity Pressure Sensing in Injection Molding

2003 ◽  
Author(s):  
Charles B. Theurer ◽  
Li Zhang ◽  
David Kazmer ◽  
Robert X. Gao
Keyword(s):  
Injection Molding ◽  
Mechanical Strain ◽  
Piezoelectric Element ◽  
Polymer Melt ◽  
High Energy ◽  
Injection Molding Process ◽  
Molding Process ◽  
Transient Model ◽  
Piezoelectric Energy ◽  
Wide Range

This paper presents the design, analysis, and validation of a self-energized piezoelectric pressure sensor that extracts energy from the pressure differential of the polymer melt during the injection molding process. To enable a self-energized sensor design, an analytical study has been conducted to establish a quantitative relationship between the polymer melt pressure and the energy that can be extracted through a piezoelectric converter. Temperature and pressure are monitored during an injection molding cycle and the performance of the piezoelectric element is evaluated with respect to a mechanically static, electrically transient model. In addition to corroboration of the proposed model, valuable statistical information about the working temperature in the prototype sensor will prove very useful in the package design of molding cavity sensors. A linear model examining the energy conversion mechanism due to interactions between the mechanical strain and the electric field developed within the piezoelectric device is established. This model is compared to the functional prototype design to evaluate the relevance of the assumptions and accuracy. The presented design enables a new generation of self-energized sensors that can be employed for the condition monitoring of a wide range of high-energy manufacturing processes.

Product Strength and Orientation Manipulation via Vibration-Assisted Injection Molding

2002 ◽  
Author(s):  
David C. Angstadt ◽  
John P. Coulter
Keyword(s):  
Thermal Conductivity ◽  
Tensile Strength ◽  
Injection Molding ◽  
Molecular Orientation ◽  
Polymer Melt ◽  
Polymer Processing ◽  
Shear Yielding ◽  
Processing Methods ◽  
Improve Product

This investigation focuses on determining why polystyrene ASTM specimens exhibit an increase in tensile strength when processed by vibration assisted injection molding (VAIM) while polycarbonate parts do not. VAIM is one of several polymer processing methods that attempt to improve product properties via manipulation of the polymer melt. Observation of birefringence patterns in VAIM processed polystyrene samples show a significant impact on molecular orientation. The same studies were conducted on opaque polycarbonate and were unable to determine the degree of molecular orientation via birefringence measurement. It was theorized that VAIM did not produce significant orientation due to its higher thermal conductivity and stiffer backbone. It has been determined by this investigation that VAIM processing does impart significant molecular orientation in polycarbonate specimens but still does not increase its UTS. It is proposed that increased molecular orientation induced by VAIM processing inhibits crazes from growing into cracks. VAIM therefore favors polymers that fail by crazing (e.g., polystyrene) rather than those that fail by shear yielding (e.g., polycarbonate).

Sign in / Sign up

Export Citation Format

Share Document