Improved fine layer patterning using soft blanket gravure printing technology

Abstract

We have developed a ‘soft blanket gravure’ (SBG) printing technology that can form patterns onto curved or three-dimensional solid surfaces using functional ink. In SBG printing, a soft and thick blanket (called a ‘soft blanket’) is employed in the similar process to conventional gravure offset printing processes. We found and reported that SBG printing could completely receive silver ink from printing plates and transfer it to target substrates more effectively than conventional gravure offset printing under various conditions. In this paper, we measured the swelling ratio of the soft blanket using two different organic solvents and performed SBG printing using printing plates with groove depths of 10–100 μm and two silver inks that contained the two different solvents. SBG printing formed patterns more than 11 μm thick and the same widths as the grooves on the printing plate (50 μm) using the optimal ink solvent. We also observed that the soft blanket could receive silver ink from the grooves without cobwebbing, in contrast to a conventional blanket. These results indicate that the SBG printing technology significantly improves the printing process because the soft blanket can absorb more solvent from silver ink.