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柔性电子卷到卷制造收卷内应力研究综述
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  • 英文篇名:Review of wound roll stress in roll-to-roll manufacturing of flexible electronics
  • 作者:陈建魁 ; 金一威 ; 周平
  • 英文作者:Jiankui Chen;Yiwei Jin;Zhouping Yin;State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology;
  • 关键词:柔性电子 ; 卷到卷制造 ; 收卷内应力 ; 张力控制 ; 内应力控制
  • 英文关键词:flexible electronics;;roll-to-roll manufacturing;;wound roll stress;;tension control;;wound roll stress control
  • 中文刊名:KXTB
  • 英文刊名:Chinese Science Bulletin
  • 机构:华中科技大学数字制造装备与技术国家重点实验室;
  • 出版日期:2019-01-29 09:01
  • 出版单位:科学通报
  • 年:2019
  • 期:v.64
  • 基金:国家自然科学基金(51475195)资助
  • 语种:中文;
  • 页:KXTB2019Z1006
  • 页数:11
  • CN:Z1
  • ISSN:11-1784/N
  • 分类号:76-86
摘要
卷到卷制造是通过柔性基板成卷连续加工的制造技术,充分利用了柔性电子可变形特性,是实现柔性电子大面积、规模化制造的最有效技术途径之一.收卷单元是卷到卷连续制造系统的必要组成,其内应力控制是影响柔性电子成品质量与生产效率的关键因素.本文详细介绍了柔性基板卷绕收卷内应力研究概况,重点综述了基于叠加原理的弹性力学方法、开尔文模型的拉普拉斯变换方法、松弛半径概念的离散建模方法和有限元方法等建立的收卷内应力研究模型;讨论了收卷速度造成的惯性力变化、基板厚度不均及弹性变形、环境温度与卷绕基板各层间卷入空气夹层、以及收卷单元压辊与气胀轴结构因素对收卷内应力的影响;分析了常用锥张力、恒张力等收卷内应力控制方法,并介绍了柔性RFID标签、燃料电池膜电极和柔性OLED等代表性柔性电子卷到卷制造系统中收卷内应力控制工程应用;最后提出了柔性电子卷到卷制造系统中收卷内应力进一步研究的关键问题:非均匀非等厚基板引起周向应力分布变化和层间接触不连续,并展望了收卷内应力研究方向.
        Flexible electronics has been widely used in many main-stream applications like flexible display, thin-film solar cell, RFID tags, flexible sensors, and so on. Roll-to-roll(R2R) is a kind of method by which flexible substrate can be processed in a continuous way. This kind of method saves time, cost, reduces delay time and increases efficiency, throughput, performance, etc. The typical R2 R system mainly consists of unwinding unit, feeding unit and winding unit, where deviation rectification control, tension control, vibration control and position control are needed. By taking full advantages of the deformation characteristics of flexible electronics, the R2R process has become one of the most effective ways in manufacturing flexible electronics. The winding unit is an essential part in the R2R system and the control of the wound roll stress in winding process is one of the main factors affecting the quality and productivity of flexible electronics. A tiny wound roll stress will cause difficulties in storage and transportation. The substrates or the electronic circuits mounted on it may be broken when the wound roll stress is too large. This paper begins with the discussion of common issues and the influence of wound roll stress in winding process. Currently, the web tension and its lateral position are two factors that mainly affect the wound roll stress. The wound roll stress will increase with the augment of the web tension. While a variation of lateral position can cause non-uniform wound roll stress in cross machine direction. Subsequently, the modelling methods and solution methods based on elastic mechanics, Laplace transformation, discrete modelling and finite element method are generalized. The four models are called elastic winding model, viscoelastic winding model, pseudo winding model and FEM winding model respectively. The elastic model is derived to predict wound roll stress of the elastic web. The viscoelastic model is developed to study how the wound roll stress changes with time after winding. In the pseudo model and the FEM model, the effect of thickness variation along the width direction is considered. Then this review analyses the effects of winding speed-induced inertia force, web deformation and its inhomogeneous thickness, temperature, air entrainment, structure of the nip roller and the core shaft on the wound roll stress. The taper tension control and constant tension control methods for wound roll stress and engineering applications in RFID tag packaging, seal lamination and flexible OLED manufacturing are also presented. Finally, this paper forecasts the key problems need to be further studied for the wound roll stress in winding process. The study of wound roll stress may focusing on the following aspects:(1) Conducting wound roll stress studies that considering the effect of thickness variation in machine direction;(2) usually we consider the wound roll as an axisymmetric cylinder, so it is necessary to develop a winding model to deal with the helical structure of the wound roll;(3) when deriving winding models, it's necessary to consider the discontinuous contact between layers.
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