Manufacturing USA: Precision Alignment of Roll-to-Roll Printing of Flexible Paper Electronics Through Modeling and Virtual Sensor-based Control

美国制造：通过建模和基于虚拟传感器的控制实现柔性纸电子产品卷对卷印刷的精确对准

• 批准号: 1907250
• 负责人: Xiaoning Jin
• 金额: $ 54.42万
• 依托单位: Northeastern University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-09-01 至 2023-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1907250&HistoricalAwards=false
• 关键词: Manufacturing; USA; Precision; Alignment; Roll

Demand is increasing for advanced manufacturing technologies that can print electronics accurately and at high speed. Roll-to-Roll printing techniques that can continuously transfer a printed electronic pattern onto a flexible substrate are very promising for high-volume production of flexible electronic devices. However, there is a significant challenge to overcome, which is that multilayer printed electronics have very tight alignment tolerance requirements, and there are no reliable tools available to monitor and control the overlay registration accuracy in real-time. To overcome this challenge, this award develops precision alignment of roll-to-roll printing using modeling and virtual sensor-based control. Another challenge is the overwhelming use of plastic as the substrate, which are manufactured from petroleum-based materials and therefore are not biodegradable, making them environmentally hazardous to produce and dispose. To address these challenges, this award pursues paper substrates as recyclable and environmentally friendly alternatives to plastic for flexible electronics. This interdisciplinary project transcends the boundaries of several important fields, including advanced materials engineering, cyber-manufacturing and data analytics. The knowledge attained from this project helps catalyze new technologies in nano and micro additive printing that feed into the innovation pipelines of the Manufacturing USA Institutes. The outcomes of this research benefit next-generation ecologically-friendly flexible electronics, such as, greener disposable sensors for patient care or lower-cost embedded home electronics. Educational activities promote interdisciplinary capstone projects and increase students? hands-on learning experience in manufacturing research. This supports the nationwide effort in educating the next generation manufacturing engineers.The goal of this project is to advance the fundamental understanding of roll-to-roll (R2R) printing of functional paper electronics. The study involves understanding the mechanism for spatial variation generation and its propagation and accumulation. The knowledge on spatial error propagation is used to develop virtual sensing to achieve unprecedented control in the creation, integration and manipulation of multilayer microstructures that form the foundation of printed paper electronics. Furthermore, this project studies materials-process-control-device performance relationships in a closed loop approach. This research expedites intelligent R2R systems with high traceability, predictability and controllability for high-resolution additive printing of flexible paper electronics, enabling a host of technologies spanning sensing, biomedical devices, and renewable energy. The development of R2R printing of electronics on paper ushers in a new era of environmentally-friendly, flexible paper devices such as water quality sensors at throwaway prices.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

对于可以准确并高速打印电子产品的高级制造技术的需求正在增加。可以连续将印刷电子图案转移到柔性基材上的滚动打印技术对于大量生产柔性电子设备非常有前途。但是，要克服的挑战是一个重大的挑战，也就是说，多层打印的电子设备具有非常紧密的一致性公差要求，并且没有可靠的工具可用于实时监视和控制覆盖层的注册精度。为了克服这一挑战，该奖项会使用建模和基于虚拟传感器的控制来制定滚动打印的精确对齐。另一个挑战是将塑料用作底物的压倒性用途，这些用作由石油基材料制造，因此不可生物降解，使它们在环境上危害生产和处置。为了应对这些挑战，该奖项将纸质基质作为可回收且环保的塑料替代品用于灵活电子产品。这个跨学科项目超越了几个重要领域的边界，包括高级材料工程，网络制造和数据分析。该项目获得的知识有助于催化纳米和微型添加剂印刷的新技术，这些印刷源于美国制造业研究所的创新管道。这项研究的结果受益于下一代对生态友好的灵活电子产品，例如，用于患者护理或较低成本嵌入式家庭电子的绿色一次性传感器。教育活动促进跨学科的顶峰项目并增加学生？在制造研究方面的动手学习经验。这支持全国性的努力教育下一代制造工程师。该项目的目的是促进对功能性纸电子产品的基本了解（R2R）打印。该研究涉及了解空间变异产生及其传播和积累的机制。关于空间误差传播的知识用于开发虚拟传感，以在创建，集成和操纵多层微结构的创建，集成和操纵中实现前所未有的控制，这些微观结构构成了印刷纸电子的基础。此外，该项目研究了闭环方法中的材料过程控制效果关系。这项研究加快了具有高可追溯性，可预测性和可控性的智能R2R系统，可用于柔性纸电子设备的高分辨率添加剂，从而实现了跨越感应，生物医学设备和可再生能源的大量技术。在一个新的时代，在环境友好，灵活的纸张设备（例如水质传感器）上开发了电子设备在纸上的纸质引擎上的开发。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛影响的审查标准来通过评估来通过评估来支持的。

项目成果

Spatial-Terminal Iterative Learning Control for Registration Error Elimination in High-Precision Roll-to-Roll Printing Systems

用于消除高精度卷对卷印刷系统中套准误差的空间终端迭代学习控制

• DOI: 10.1115/msec2023-106259
• 发表时间: 2023
• 期刊: American Society of Mechanical Engineers
• 作者: Wang, Zifeng;Jin, Xiaoning
• 通讯作者: Jin, Xiaoning

Virtual sensing and virtual metrology for spatial error monitoring of roll-to-roll manufacturing systems

用于卷对卷制造系统空间误差监控的虚拟传感和虚拟计量

• DOI: 10.1016/j.cirp.2019.04.108
• 发表时间: 2019
• 期刊: CIRP Annals
• 作者: Jin, Xiaoning;Shui, Huanyi;Shpitalni, Moshe
• 通讯作者: Shpitalni, Moshe

Large‐Scale Manufacturing of Pattern‐Integrated Paper Li‐Ion Microbatteries through Roll‐to‐Roll Flexographic Printing

• DOI: 10.1002/admt.202200303
• 发表时间: 2022-05
• 期刊: Advanced Materials Technologies
• 影响因子: 6.8
• 作者: Ying Wang;D. Cao;Xiao Sun;Hao-Ming Ren;T. Ji;Xiaoning Jin;J. Morse;Barbara Stewart;Hongli Zhu