SNM: Physics Guided Innovation of Integrated Flash-Light-Sintering, Continuous Nanomaterial Synthesis and Roll-To-Roll Deposition Processes

SNM：集成闪光烧结、连续纳米材料合成和卷对卷沉积工艺的物理引导创新

• 批准号: 1449383
• 负责人: Chih-hung Chang
• 金额: $ 150万
• 依托单位: Oregon State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2014
• 资助国家: 美国
• 起止时间: 2014-12-01 至 2019-11-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1449383&HistoricalAwards=false
• 关键词: SNM; Physics; Guided; Innovation; Integrated

CBET-1449383Chang, Oregon State UniversityContinuous and patterned thin-films with controlled geometries are poised to make a disruptive impact in applications including pervasive sensing and communications, wearable health-monitoring, environmental sensing, energy efficient buildings and transportation, renewable energy and energy storage. In this project, the PIs will address the current bottleneck of high manufacturing costs for large-volume production of such thin-films, to enhance U.S. manufacturing competitiveness on the global stage and enable improved quality of life via widespread deployment of corresponding thin-film devices. The primary research scope will focus on investigating the fundamental multi-physical phenomena over multiple length scales that underlie a transformational and highly-scalable nanoparticle-ink sintering process, i.e., Flash-Light-Sintering. This will enhance understanding of the interaction between optically induced nanoparticle heating and nanoparticle fusion in a collection of nanoparticles, leading to a better understanding of the implications of these phenomena in scalable nanomanufacturing. This fundamental knowledge will lead to the innovation of advanced high-throughput and low-cost methods for industrial scale manufacturing of thin-films. As part of this project, The PIs will train graduate students to develop hands-on educational modules based on this research, requiring the students to analyze and summarize results, extract the underlying principles, create demonstration experiments, and use these modules to teach parts of graduate courses. The PIs will also engage undergraduates via existing undergraduate mentoring programs as well as high school students via the Apprenticeships in Science and Engineering (ASE) program. The primary focus group of ASE has been traditionally underrepresented students. The use of focused hands-on experimental projects as a teaching tool will allow these students to develop a deep appreciation and interest in the multiple physical phenomena and processes associated with scalable nanomanufacturing processes.The goals of this proposal are to investigate the fundamental multiscale and multiphysical phenomena underlying a transformational and highly-scalable Nanoparticle-ink (NP-ink) sintering process, i.e., Flash-Light-Sintering (FLS), and to use this knowledge to guide the creation of novel, scalable processes that combine FLS with equally scalable Microreactor-Assisted Nanoparticle Synthesis (MANS) and Roll-to-Roll (R2R) NP-ink deposition. These advanced processes will possess unmatched capabilities for low-cost, high-throughput, multi-materials capable manufacturing of patterned and continuous thin-films with controlled nano-scale density over large-area flexible substrates. In FLS, sintering times can be up to 100x faster while operation and equipment costs can be several orders lower than conventional NP sintering methods. The PIs will overcome key scientific and technical gaps including poor understanding of the physics of FLS, limited multimaterials capability, costly and discontinuous NP-ink synthesis, and costly tooling for patterning NP-inks that have limited the full utilization of highly scalable integrated FLS-R2R processes.The PIs will develop multi-scale, multi-physical models to understand the link between the optically-induced nanoparticle heating and densification of nanoparticles. These models, along with extensive experimental characterization will uncover new knowledge on the effects of FLS process parameters and NP-ink characteristics on the characteristics of the sintered thin-films. This new knowledge will guide the design of a novel dual-band FLS-R2R process for high-throughput FLS of semiconductor NPs that typically have low optically induced heating effects. This process, along with novel methods for controlling FLS by tailoring the chemical composition of the nanoparticles, will enable significantly expanded multimaterials capability of FLS. The design and integration of scalable MANS processes with these novel FLS and R2R processes will enable additional degrees of multimaterial flexibility and reduced costs for the use of integrated FLS-R2R systems. The above efforts will also guide the design a new gravure-less FLS-R2R process to minimize the tooling costs associated with fabrication of patterned thin-films using NP-inks.

CBET-1449383张，俄勒冈州州立大学具有受控几何形状的连续和图案化薄膜有望在应用中产生颠覆性影响，包括普及传感和通信，可穿戴健康监测，环境传感，节能建筑和运输，可再生能源和能源存储。在该项目中，PI将解决目前大批量生产此类薄膜的高制造成本瓶颈，以提高美国在全球舞台上的制造竞争力，并通过广泛部署相应的薄膜设备来提高生活质量。主要的研究范围将集中在研究多个长度尺度上的基本多物理现象，这些现象是一个转型和高度可扩展的纳米颗粒-墨水烧结过程的基础，即，闪光烧结。这将增强对纳米颗粒集合中的光诱导纳米颗粒加热和纳米颗粒融合之间的相互作用的理解，从而更好地理解这些现象在可扩展的纳米制造中的影响。这些基础知识将导致先进的高通量和低成本的方法，用于工业规模的薄膜制造的创新。作为该项目的一部分，PI将培训研究生根据这项研究开发实践教育模块，要求学生分析和总结结果，提取基本原理，创建演示实验，并使用这些模块教授研究生课程的一部分。PI还将通过现有的本科生辅导计划吸引本科生，并通过科学与工程学徒（ASE）计划吸引高中生。ASE的主要重点群体历来是代表性不足的学生。使用专注的动手实验项目作为教学工具，将使这些学生对与可扩展的纳米制造过程相关的多种物理现象和过程产生深刻的理解和兴趣。本提案的目标是研究转换和高度可扩展的纳米颗粒油墨（NP油墨）烧结过程的基本多尺度和多物理现象，即，闪光烧结（FLS），并使用这一知识来指导创造新的，可扩展的过程，结合联合收割机FLS与同样可扩展的微反应器辅助纳米颗粒合成（MANS）和卷到卷（R2 R）NP油墨沉积。这些先进的工艺将具有无与伦比的低成本、高产量、多材料能力，能够在大面积柔性基板上制造具有受控纳米级密度的图案化和连续薄膜。在FLS中，烧结时间可以快100倍，而操作和设备成本可以比传统的NP烧结方法低几个数量级。PI将克服关键的科学和技术差距，包括对FLS物理学的理解不足，有限的多材料能力，昂贵且不连续的NP油墨合成，以及用于图案化NP油墨的昂贵工具，这些工具限制了高度可扩展的集成FLS-R2 R工艺的充分利用。多物理模型，以了解光诱导纳米颗粒加热和纳米颗粒致密化之间的联系。这些模型，沿着与广泛的实验表征将揭示新的知识的影响FLS工艺参数和NP-油墨的特性上的烧结薄膜。这一新的知识将指导设计一种新的双波段FLS-R2 R工艺，用于通常具有低光致加热效应的半导体NP的高通量FLS。该过程，沿着通过调整纳米颗粒的化学组成来控制FLS的新方法，将使FLS的多材料能力显著扩展。可扩展的MANS工艺与这些新型FLS和R2 R工艺的设计和集成将使多材料灵活性的程度增加，并降低集成FLS-R2 R系统的使用成本。上述努力还将指导设计一种新的无凹版FLS-R2 R工艺，以最大限度地减少与使用NP油墨制造图案化薄膜相关的工具成本。

项目成果

Intense Pulsed Light unprinting for reducing life-cycle stages in recycling of coated printing paper

• DOI: 10.1016/j.jclepro.2019.05.387
• 发表时间: 2019-09-20
• 期刊: JOURNAL OF CLEANER PRODUCTION
• 影响因子: 11.1
• 作者: Dexter, Michael;Rickman, Keri;Malhotra, Rajiv
• 通讯作者: Malhotra, Rajiv

Shape-Tuned Junction Resistivity and Self-Damping Dynamics in Intense Pulsed Light Sintering of Silver Nanostructure Films

• DOI: 10.1021/acsami.8b17644
• 发表时间: 2019-01-23
• 期刊: ACS APPLIED MATERIALS & INTERFACES
• 影响因子: 9.5
• 作者: Hwang, Hyun-Jun;Malhotra, Rajiv
• 通讯作者: Malhotra, Rajiv

Modeling nanoscale temperature gradients and conductivity evolution in pulsed light sintering of silver nanowire networks

• DOI: 10.1088/1361-6528/aae368
• 发表时间: 2018-12-14
• 期刊: NANOTECHNOLOGY
• 影响因子: 3.5
• 作者: Dexter, Michael;Pfau, Andrew;Malhotra, Rajiv
• 通讯作者: Malhotra, Rajiv

The Coupling Between Densification and Optical Heating in Intense Pulsed Light Sintering of Silver Nanoparticles

银纳米颗粒强脉冲光烧结致密化与光加热之间的耦合

• DOI: 10.1115/msec2016-8693
• 发表时间: 2016
• 期刊: ASME 2016 11th International Manufacturing Science and Engineering Conference
• 作者: Bansal, Shalu;Chang, Chih-Hung;Malhotra, Rajiv
• 通讯作者: Malhotra, Rajiv

Solution-based & Printable Functional Materials for Smart Fabrics

基于解决方案

• 发表时间: 2018
• 期刊: TMS 2018 147th annual meeting and exhibition
• 作者: Gao, Z.;Li, Shujie;He, Yujuan;Chang, Chih-hung;Hwang, Hyun-Jun;Malhotra, Rajiv.
• 通讯作者: Malhotra, Rajiv.