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Multi-scale ordering in highly stretchable polymer semiconducting films
摘要： Stretchable semiconducting polymers have been developed as a key component to enable skin-like wearable electronics, but their electrical performance must be improved to enable more advanced functionalities. Here, we report a solution processing approach that can achieve multi-scale ordering and alignment of conjugated polymers in stretchable semiconductors to substantially improve their charge carrier mobility. Using solution shearing with a patterned microtrench coating blade, macroscale alignment of conjugated-polymer nanostructures was achieved along the charge transport direction. In conjunction, the nanoscale spatial confinement aligns chain conformation and promotes short-range π–π ordering, substantially reducing the energetic barrier for charge carrier transport. As a result, the mobilities of stretchable conjugated-polymer films have been enhanced up to threefold and maintained under a strain up to 100%. This method may also serve as the basis for large-area manufacturing of stretchable semiconducting films, as demonstrated by the roll-to-roll coating of metre-scale films.
关键词： charge carrier mobility,conjugated polymers,solution shearing,stretchable semiconductors,roll-to-roll coating,multi-scale ordering
更新于2025-11-19 16:56:35
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A roller posture adjustment device with remote-center-of-motion for roll-to-roll printed electronics
摘要： Nonuniform web tension has a great negative effect on product quality of roll-to-roll printed electronics. In this paper, a roller posture adjustment device with remote-center-of-motion (RCM) characteristic is proposed to guarantee web tension uniformity. The device combines a high-stiffness spherical air bearing (SAB) and a multi-degree-of-freedom flexure-based mechanism. The nonuniform web tension in lateral direction can be divided into an equivalent force and two equivalent moments. The equivalent moments are caused by the nonuniformity of the web tension. By adjusting the roller angle around y and z-axes, the equivalent moments can be eliminated to guarantee the web tension uniformity. The multi-DOF flexure-based mechanism is composed of a linear mechanism, a rotary mechanism and a 3-DOF off-plane mechanism. Besides, the RCM characteristic of the proposed device is realized to eliminate extra parasitic movement when the roller posture is changed. Based on pseudo-rigid-body model (PRB-M) method, the theoretical analysis is conducted to evaluate the kinematics, stiffness and dynamics of the device. Moreover, the parameter optimization is conducted to maximize the first two resonance frequencies of the system. After that, finite element analysis is conducted to validate the established models. Finally, a prototype of the proposed device is fabricated performance verification. The experimental results show that the proposed device has a workspace of 10.22 mrad and 8.16 mrad about two working axes with center shifts of the RCM point less than 0.75%, which demonstrate the superior property of the proposed device.
关键词： Flexure-based mechanism,Micro-positioning,Roll-to-roll printed electronics,Remote-center-of-motion
更新于2025-09-23 15:21:21
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Roll-to-roll fabrication of touch-responsive cellulose photonic laminates
摘要： Hydroxypropyl-cellulose (HPC), a derivative of naturally abundant cellulose, can self-assemble into helical nanostructures that lead to striking colouration from Bragg reflections. The helical periodicity is very sensitive to pressure, rendering HPC a responsive photonic material. Recent advances in elucidating these HPC mechano-chromic properties have so-far delivered few real-world applications, which require both up-scaling fabrication and digital translation of their colour changes. Here we present roll-to-roll manufactured metre-scale HPC laminates using continuous coating and encapsulation. We quantify the pressure response of the encapsulated HPC using optical analyses of the pressure-induced hue change as perceived by the human eye and digital imaging. Finally, we show the ability to capture real-time pressure distributions and temporal evolution of a human foot-print on our HPC laminates. This is the first demonstration of a large area and cost-effective method for fabricating HPC stimuli-responsive photonic films, which can generate pressure maps that can be read out with standard cameras.
关键词： mechano-chromic,Hydroxypropyl-cellulose,pressure mapping,self-assemble,photonic laminates,Bragg reflections,roll-to-roll fabrication,helical nanostructures
更新于2025-09-23 15:21:21
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Late-stage Customization in Volume Production of Organic Photovoltaics
摘要： Organic photovoltaics (OPV) in free-form shapes have become a unique feature compared to other thin-film photovoltaic technologies. The ability to conform coated layers to any form of shape or structure is a game changer for OPV and creates a paradigm shift in conventional energy businesses. As urban growth prevails, the energy requirement must be compensated by modern means and OPVs provide unique properties where its form or shape can be fully customized. This creates a synergy as they are then easily integrated onto structures or even products. By doing so not only the space requirements are diminished but the energy is delivered directly to the point of use rather than having them transported from central harvesting. The present communication discusses the advances in realizing such free-from patterns by structuring the functional layers to shape after they have been deposited which is referred to as late-stage customization. Using this approach, a pre-coated generic OPV material can be converted into any design upon customer request. The advantages include easier planning, shorter lead times in production as well as paving the way towards lean manufacturing.
关键词： renewable energies,mass production,organic photovoltaics (OPV),laser scribing,slot-die coating,module customization,roll-to-roll fabrication,dielectric material
更新于2025-09-23 15:21:01
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Roll-to-Roll Slot-Die Coated P-I-N Perovskite Solar Cells Using Acetonitrile Based Single Step Perovskite Solvent System
摘要： Roll-to-roll coating of all active layers is demonstrated for a P-I-N perovskite solar cell stack, using a single step perovskite ink with an acetonitrile solvent system and flexible plastic substrate. A slot-die coating roll-to-roll process (with a common coating speed for all layers) is developed by using appropriate length meniscus guides as part of the coating head for each ink rheology. High performance devices are demonstrated with four roll-to-roll slot-die coated layers and evaporated top electrode. The drying conditions of the perovskite layer are optimized and found to be critical to achieving good performance. Multi solvent blend systems for the electron collection layer are developed that are more industrially compatible than the commonly used chlorobenzene solvent system and make use of a gradient of solvent volatilities to give both good macro film formation and rapid drying. A stabilised power conversion efficiency of 12.2% is demonstrated, that is the highest reported to date for devices with all layers other than the top electrode deposited roll-to-roll. This work demonstrates the feasibility of a roll-to-roll fabrication process for perovskite solar cells that could be transferred to a fully inline roll-to-roll process with all coating and drying stages made sequentially on one line running at a common coating speed and further demonstrates the potential to produce high efficiency photovoltaics using roll-to-roll fabrication methods.
关键词： Stabilised power conversion efficiency,Perovskite solar cells,Slot-die coating,Roll-to-roll,Acetonitrile solvent system
更新于2025-09-23 15:21:01
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Perovskite Photovoltaics on Roll-To-Roll Coated Ultra-thin Glass as Flexible High-Efficiency Indoor Power Generators
摘要： Indoor perovskite photovoltaics can help power the internet of things revolution, being highly ef?cient, low-cost, printable, and compatible with ?exible substrates. Castro-Hermosa et al. develop ?exible perovskite cells on roll-to-roll coated ultra-thin glass with excellent optoelectrical and mechanical properties, delivering ef?ciencies of 20.6%–22.6% under 200–400 lx LED illumination.
关键词： Flexible high-efficiency indoor power generators,Perovskite photovoltaics,LED illumination,Roll-to-roll coated ultra-thin glass
更新于2025-09-23 15:21:01
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High-Resolution, High-Aspect-Ratio Printed and Plated Metal Conductors Utilizing Roll-to-Roll Microscale UV Imprinting with Prototype Imprinting Stamps
摘要： Micron-scale, high-aspect-ratio features were imprinted by a roll-to-roll process into a UV-curable polymer and used to create high-current-carrying conductive networks on plastic substrates. A stamp fabrication method was developed to create low-cost, rapidly produced roll-to-roll imprinting stamps, which can mold features from 3 μm to 1 mm wide. Isolated raised features 50 μm high were molded from a 25-μm-thick layer of UV-curable resin by displacing resin into raised features in the stamp. Substrates with imprinted capillary channels were used to form electrical conductors by printing a silver ink into reservoirs connected to the channels and allowing capillary flow to coat the channel. Copper electroless plating then filled the channels. The conductors demonstrate high resolution, high aspect ratio (～5:1 height:width), low resistance per length, and easy integration into networks. This roll-to-roll imprinting process provides a foundation for high-throughput manufacturing of high-resolution printed electronics.
关键词： high-aspect-ratio,conductive networks,roll-to-roll imprinting,UV-curable polymer,printed electronics
更新于2025-09-23 15:21:01
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Micro/Nanolithography - A Heuristic Aspect on the Enduring Technology || Large-Area Nanoimprint Lithography and Applications
摘要： Large-area nanoimprint lithography (NIL) has been regarded as one of the most promising micro/nano-manufacturing technologies for mass production of large-area micro/nanoscale patterns and complex 3D structures and high aspect ratio features with low cost, high throughput, and high resolution. That opens the door and paves the way for many commercial applications not previously conceptualized or economically feasible. Great progresses in large-area nanoimprint lithography have been achieved in recent years. This chapter mainly presents a comprehensive review of recent advances in large-area NIL processes. Some promising solutions of large-area NIL and emerging methods, which can implement mass production of micro- and nanostructures over large areas on various substrates or surfaces, are described in detail. Moreover, numerous industrial-level applications and innovative products based on large-area NIL are also demonstrated. Finally, prospects, challenges, and future directions for industrial scale large-area NIL are addressed. An infrastructure of large-area nanoimprint lithography is proposed. In addition, some recent progresses and research activities in large-area NIL suitable for high volume manufacturing environments from our Labs are also introduced. This chapter may provide a reference and direction for the further explorations and studies of large-area micro/nano patterning technologies.
关键词： roller-type NIL,large-area micro/nano patterning,roll-to-roll NIL,large-area nanoimprint lithography,full wafer NIL,roll-to-plate NIL
更新于2025-09-19 17:15:36
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Properties of Nitrogen/Silicon Doped Vertically Oriented Graphene Produced by ICP CVD Roll-to-Roll Technology
摘要： Simultaneous mass production of high quality vertically oriented graphene nanostructures and doping them by using an inductively coupled plasma chemical vapor deposition (ICP CVD) is a technological problem because little is understood about their growth mechanism over enlarged surfaces. We introduce a new method that combines the ICP CVD with roll-to-roll technology to enable the in-situ preparation of vertically oriented graphene by using propane as a precursor gas and nitrogen or silicon as dopants. This new technology enables preparation of vertically oriented graphene with distinct morphology and composition on a moving copper foil substrate at a lower cost. The technological parameters such as deposition time (1–30 min), gas partial pressure, composition of the gas mixture (propane, argon, nitrogen or silane), heating treatment (1–60 min) and temperature (350–500 ?C) were varied to reveal the nanostructure growth, the evolution of its morphology and heteroatom’s intercalation by nitrogen or silicon. Unique nanostructures were examined by FE-SEM microscopy, Raman spectroscopy and energy dispersive X-Ray scattering techniques. The undoped and nitrogen- or silicon-doped nanostructures can be prepared with the full area coverage of the copper substrate on industrially manufactured surface defects. Longer deposition time (30 min, 450 ?C) causes carbon amorphization and an increased fraction of sp3-hybridized carbon, leading to enlargement of vertically oriented carbonaceous nanostructures and growth of pillars.
关键词： vertically oriented graphene (VOG),Li-ion battery,roll-to-roll technology,inductively coupled plasma chemical vapor deposition (ICP CVD),supercapacitor
更新于2025-09-19 17:15:36
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Evaporation‐Free Nonfullerene Flexible Organic Solar Cell Modules Manufactured by An All‐Solution Process
摘要： To ensure laboratory-to-industry transfer of next-generation energy harvesting organic solar cells (OSCs), it is necessary to develop flexible OSC modules that can be produced on a continuous roll-to-roll basis and to apply an all-solution process. In this study, nonfullerene acceptors (NFAs)-based donor polymer, SMD2, is newly designed and synthesized to continuously fabricate high-performance flexible OSC modules. Also, multifunctional hole transport layers (HTLs), WO3/HTL solar bilayer HTLs, are developed and applied via an all-solution process called “ProcessOne” into inverted structure. SMD2, the donor terpolymer, has a deep highest occupied molecular orbital (HOMO) level and can achieve a power conversion efficiency (PCE) of 11.3% with NFAs without any pre-/post-treatment because of its optimal balance between crystallinity and miscibility. Furthermore, the integration of multifunctional HTLs enables the recovery of the drop in open circuit voltage (VOC) caused by a mismatch in energy levels between the deep HOMO level of the NFAs-based bulk-heterojunction layer and the solution-processed HTLs. Also, the photostability under ultraviolet-exposure necessary for “ProcessOne” is greatly improved because of the integration of multifunctional HTLs. Consequently, because of the synergistic effects of these approaches, the flexible OSC modules fabricated in an industrial production line have a PCE of 5.25% (Pmax = 419.6 mW) on an active area of 80 cm2.
关键词： roll-to-roll process,all-solution process,flexible modules,nonfullerene acceptors,organic solar cells
更新于2025-09-19 17:13:59