CAREER: Conformal Stamp Printing for 3D Curvilinear Electronics Manufacturing

职业：用于 3D 曲线电子制造的保形印章打印

• 批准号: 2224645
• 负责人: Cunjiang Yu
• 金额: $ 50万
• 依托单位: Pennsylvania State Univ University Park
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-01-01 至 2022-09-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2224645&HistoricalAwards=false
• 关键词: CAREER; Conformal; Stamp; Printing; 3D

Electronics constructed in 3D curvilinear layouts have many applications; examples include smart contact lens with sensors integrated, wide field-of-view cameras from curved image sensor arrays, and spherical helix antennas with high radiation efficiency. However, it is very challenging to create 3D curvilinear electronics due to manufacturing technology gaps. This Faculty Early Career Development (CAREER) award supports fundamental research to provide needed knowledge to develop conformal stamp printing approach for 3D curvilinear electronics manufacturing. 3D curvilinear electronics made from conformal stamp printing can be used in healthcare, space, telecommunication, and energy industries. Therefore, outcomes from this research will benefit the U.S. economy and society. The award will also support educational and outreach activities, such as providing learning opportunities to high school students and their teachers, offering research experiences for undergraduate students (especially those from the underrepresented groups), and disseminating the latest science and engineering knowledge to the general public.Conformal stamp printing involves employing an inflated elastomeric balloon (conformal stamp) to pick-up and print electronic components (inks) onto curvilinear surfaces to create 3D curvilinear electronics. The first research objective is to establish the relationship between the deformation and induced strain in the stamp. To achieve this objective, the stamp's material properties, including strain-stress relationship and modulus, will be characterized by tension tests of thin elastomeric sheets. Employing the measured properties, both analytical models based on strain energy in the stamp and finite element simulations of inflated stamp under deformation will be used to predict the quantitative relationship between the deformation and associated strain. The second objective is to quantify the effects of stamp peeling speed on the interfacial adhesion strength between stamp and inks. To achieve this objective, a model of adhesion strength related to peeling speed will be built based on the energy release rate when peeling to crack an interface between rigid silicon (ink) and viscoelastic elastomer (stamp). After being verified by experiments, the model will be used to predict the effects of peeling speed on interfacial adhesion strength. The third objective is to establish the relationship between the deformation of the stamp and the deformation, strain and pattern distortion of the inks. To achieve this objective, finite element simulations of the inks at deformed states during and after printing will be performed. After being verified by experiments, the simulations will be utilized to capture the inks' deformation, strain and pattern distortion with various deformation conditions of the stamp.

以 3D 曲线布局构建的电子产品有许多应用；示例包括集成传感器的智能隐形眼镜、曲面图像传感器阵列的宽视场相机以及具有高辐射效率的球形螺旋天线。然而，由于制造技术差距，创建 3D 曲线电子产品非常具有挑战性。该学院早期职业发展 (CAREER) 奖项支持基础研究，以提供开发 3D 曲线电子制造的保形印章打印方法所需的知识。由保形印章印刷制成的 3D 曲线电子产品可用于医疗保健、太空、电信和能源行业。因此，这项研究的成果将有利于美国经济和社会。该奖项还将支持教育和外展活动，例如为高中生及其教师提供学习机会，为本科生（特别是来自弱势群体的学生）提供研究经验，以及向公众传播最新的科学和工程知识。 保形邮票印刷涉及使用充气的弹性气球（保形邮票）拾取电子元件（油墨）并将其印刷到曲线表面上，以 创建 3D 曲线电子产品。第一个研究目标是建立压模中变形与诱发应变之间的关系。为了实现这一目标，印模的材料特性，包括应变-应力关系和模量，将通过弹性薄板的拉伸测试来表征。利用测量到的特性，基于印模应变能的分析模型和变形下膨胀印模的有限元模拟将用于预测变形和相关应变之间的定量关系。第二个目标是量化印章剥离速度对印章和油墨之间界面粘合强度的影响。为了实现这一目标，将根据剥离以破裂刚性硅（墨水）和粘弹性体（印章）之间的界面时的能量释放速率，建立与剥离速度相关的粘合强度模型。经过实验验证后，该模型将用于预测剥离速度对界面粘合强度的影响。第三个目标是建立印模变形与油墨变形、应变和图案扭曲之间的关系。为了实现这一目标，将对印刷过程中和印刷后变形状态下的油墨进行有限元模拟。经过实验验证后，将利用模拟来捕捉印模各种变形条件下油墨的变形、应变和图案变形。