High-precision register error control using active-motion-based roller in roll-to-roll gravure printing

Abstract

The roll-to-roll (R2R) gravure printing method is increasingly being utilized to fabricate electronic devices such as organic thin-film transistor (OTFT), radio-frequency identification (RFID) tags, and flexible PCB owing to its characteristics of high throughput and large area. High precision registration is crucial to satisfy the demand for device miniaturization, the improvement of resolution and accuracy. This paper presents a novel register control method that uses an active motion-based roller (AMBR) to reduce register error in R2R gravure printing. Instead of shifting the phase of the downstream printing roller, which leads to undesired tension disturbance, the 1 degree-of-freedom (1-DOF) mechanical device AMBR is used to compensate for web elongation by controlling its motion according to the register error. The performance of the proposed control method is verified through simulations and experiments, and the results show that the proposed register control method using the AMBR could maintain a register error under ±15 µm.