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Roll-to-Roll Coating Technology and Its Applications: A Review

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Abstract

Roll-to-roll (R2R) coating technologies, with their advantages in terms of high throughput and environmental friendliness, are expected to be used at various industrial sites. Thin-film and thick-film forming can be conducted by various techniques that can be installed with R2R systems including dip coating, knife-over-edge coating, slot-die coating, direct- and micro-gravure coating, and spray coating. In this review, coating techniques are introduced from the perspective of process optimization along with examples of applications. Moreover, R2R web handling is also covered for its relationship with the coating process. Process conditions are obtained by presenting the mathematical modeling of each process and a real coating window is presented with surveyed data. Applications of coating technologies focus on printed electronic devices because of their ability to use soluble materials. State-of-art R2R vacuum coating and lab-scale coating without R2R are not discussed in this review. This summary of R2R coating techniques and applications aims to give guidelines for operation and long-term prospects for advanced coating manufacturing.

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Abbreviations

f r :

flow rate of liquid

u :

control input

v ref :

velocity reference

V :

actual line velocity of web/roller

μ E :

effective coefficient of web/roller friction

β:

wrap angle

T 1 :

upstream tension

T 2 :

downstream tension

h 0 :

coating gap (distance from the discharger or slot to the substrate)

H :

sum of coating gap and radius of backup roller

t w :

thickness of the web

a :

centroid of geometric shape in Fig. 2(a)

b :

axis of rotation in Fig. 2(a)

R mean :

distance between the web and a

e :

distance between a and b

θ +Φ:

angle between a and b

W SL a :

surface energy at solid-liquid interfaces

γ L :

surface tension of liquid

θ L :

contact angle of liquid

ε eq :

equivalent stain within a web span

ε eq e :

equivalent elastic strain

ε eq th :

equivalent thermal stain

D d :

duration of drying

l d :

length of drying section

t wet :

wet thickness of the coated layer

μ:

viscosity of liquid

ρl :

density of the solid in liquid

g :

acceleration due to gravity (9.80665 m/s2)

σ:

surface tension of liquid

C a :

cte]apillary number (Ca

t dry :

dry thickness of the coated layer

ρ s :

density of the solid in a dried film

n :

number of coating stripes

w :

width of one coating stripe

U g :

actual line velocity of roller (reverse coating case)

V c :

cell volume per unit area of roller surface

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Authors and Affiliations

  1. Department of Mechanical Design and Production Engineering, Konkuk University, 120, Neungdong-ro, Gwangjin-gu, Seoul, 05029, South Korea

    Janghoon Park & Keehyun Shin

  2. School of Mechanical Engineering, Changwon National University, 20, Changwondaehak-ro, Uichang-gu, Changwon-si, Gyeongsangnam-do, 51140, South Korea

    Changwoo Lee

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  1. Janghoon Park
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  2. Keehyun Shin
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  3. Changwoo Lee
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Correspondence to Changwoo Lee.

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Park, J., Shin, K. & Lee, C. Roll-to-Roll Coating Technology and Its Applications: A Review. Int. J. Precis. Eng. Manuf. 17, 537–550 (2016). https://doi.org/10.1007/s12541-016-0067-z

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  • DOI: https://doi.org/10.1007/s12541-016-0067-z

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