Analytical study on web deformation by tension in roll-to-roll printing process

Abstract

Recently, flexible devices have gained high intentions for flexible display, Radio Frequency Identification (RFID), bio-sensor and so on. For manufacturing of the flexible devices, roll-to-roll process is a good candidate because of its low production cost and high productivity. Flexible substrate has a non-uniform deformation distribution by tension. Because the roll-to-roll process carries out a number of overlay printing processes, the deformation affect overlay printing precision and printable areas. In this study, the deformation of flexible substrate was analyzed by using finite element analysis and it was verified through experiments. More deformation occurred in the middle region in the direction parallel to rolling of the flexible substrate. It is confirmed through experiments and analysis that deformation occurs less at the both ends than in the middle region. Based on these results, a hourglass roll is proposed as a mechanical design of the roll to compensate the non-uniform deformation of the flexible substrate. In the hourglass roll, high stiffness material is used in the core and low stiffness material such as an elastic material is wrapped. The diameter of the core roll was designed to be the minimum at the middle and the maximum at both ends. We tried to compensate the non-uniform deformation distribution of the flexible substrate by using the variation of the contact stiffness between the roll and the flexible substrate. Deformation distribution of flexible substrates was confirmed by finite element analysis by applying hourglass roll shape. In the analysis when using the hourglass roll, it is confirmed that the stress distribution is compensated by about 70% and the strain distribution is compensated by about 67% compared to the case using the hourglass roll. To verify the compensation of the non-uniform deformation distribution due to the tension, deformation measurement experiment when using the proposed hourglass roll was carried out. Experiments have shown that the distribution of deformation is compensated by about 34%. From the results, we verified the performance of the proposed.