Study of a Dot-patterning Process on Flexible Materials using Impact Print-Type Hot Embossing Technology

Summary

Impact print-type hot embossing technology uses an impact header to engrave dot patterns on flexible materials in real time. This technology has a control system for controlling the on-off motion and position of the impact header to create dot patterns with various widths and depths on different polymer films.

Abstract

Here we present our study on an impact print-type hot embossing process which can create dot patterns with various designs, widths, and depths in real time on polymer film. In addition, we implemented a control system for the on-off motion and position of the impact header to engrave different dot patterns. We performed dot patterning on various polymer films, such as polyester (PET) film, polymethyl methacrylate (PMMA) film, and polyvinyl chloride (PVC) film. The dot patterns were measured using a confocal microscope, and we confirmed that the impact print-type hot embossing process produces fewer errors during the dot patterning process. As a result, the impact print-type hot embossing process is found to be suitable for engraving dot patterns on different types of polymer films. In addition, unlike the conventional hot embossing process, this process does not use an embossing stamp. Therefore, the process is simple and can create dot patterns in real time, presenting unique advantages for mass production and small-quantity batch production.

Introduction

Researchers are actively attempting to miniaturize existing devices and displays and increase the flexibility of these devices^1,2. To reduce the width and depth of electrical channels to the micro or nano scale, high-precision technology is necessary. In addition, to increase the flexibility of these devices, the patterns of the electrical channels must be located on a flexible material, such as a polymer film^3,4. To meet these conditions, the study of ultrafine microprocessing technology is actively underway.

Ultrafine micr....

Protocol

1. Fabrication of the impact print-type hot embossing process

1. Make model 1 and combine it with an X-stage (see Figure 1).
   NOTE: It is recommended that Model 1 be made of aluminum to avoid heat being conducted onto the X-stage. Moreover, it is recommended that the length of Model 1 be the distance between the surface of the heat plate and the lowest height of the bearing plate of the Z-stage as the design of Model 1 varies with the size of the heat plate.
2. Combine the X-stage and Z-stage and assemble the Z-stage and Model 2.
   NOTE: Ensure that Model 2 is made of a metal that can endure the heat from the he....

Results

The impact print-type hot embossing process is a process that can be used to engrave dot patterns onto a polymer film in real time, as shown in Figure 1. This process can resolve the issues of the high cost and long times for pattern replacement associated with the existing hot embossing process. A control circuit was constructed, as shown in Figure 2 (see steps 2.3–2.3.9), using the DAQ, OP-AMP, and power supply to carve patterns on various types of polymer fil.......

Discussion

In this study, we implemented the impact print-type hot embossing process and engraved dot patterns with various widths and depths onto a range of polymer films in real time. Among the protocol steps, two steps should be critically considered among all steps. The first is the setting of the temperature of the heat plate (step 3.3.3), and the second is the setting of the initial position of the impact header (step 3.5.1). In step 3.3.3, if the temperature of the heat plate is too high, it becomes difficult to form a patte.......

Materials

List of materials used in this article

Name	Company	Catalog Number	Comments
0.3mm High Quality Clear Rigid Packaging PVC Film Roll For Vacuum Forming	Sunyo	SY1023	PVC film / Thickness : 300µm
Acryl(PMMA) film	SEJIN TS	C200	PMMA film / Thickness : 175µm
Confocal Laser Scanning Microscope: 3D-Topography for Materials Analysis and Testing	Carl Zeiss	LSM 700	3D confocal microscope / Supporting Mode : 2D, 2.5D, 3D topography
DAQ board	NATIONAL INSTRUMENTS	USB-6211	Control board for two stage and impact header / 16 inputs, 16-bit, 250kS/s, Multifunction I/O
DC Power Supply	SMART	RDP-305AU	3 channel power supply / output voltage : 0~30V, Output current : 0~5A
L511 stage	PI	L511.20SD00	Z-stage / Travel range : 52mm
Large Digital Hotplate	DAIHAN Scientific	HPLP-C-P	Heatplate / Max Temp : 350ºC
M531 stage	PI	M531.2S1	X-stage / Travel range : 306mm
Mylar Polyester PET films	CSHyde	48-2F-36	PET film / Thickness : 50µm
OPA2541	BURR-BROWN	OPA2541BM	OP-AMP / Output currents : 5A, output voltage : ±40V