Manufacturing USA: High-Resolution Flexography for Printed Electronics Using Nanoporous Carbon Nanotube Stamps

美国制造：使用纳米多孔碳纳米管印章进行印刷电子产品的高分辨率柔印

• 批准号: 1826216
• 负责人: Anastasios John Hart
• 金额: $ 36万
• 依托单位: Massachusetts Institute of Technology
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-08-15 至 2023-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1826216&HistoricalAwards=false
• 关键词: Manufacturing; USA; Resolution; Flexography; Printed

For centuries, innovations in printing technologies have gone hand-in-hand with advances in communication, education, and industrialization. Even though digital media has replaced a significant fraction of print media, further breakthroughs in printing technologies are now essential for scalable manufacturing of electronic devices in new formats, for example, on windows, contact lenses, and product packaging. However, the inability to print electronic materials with micron-scale resolution at high throughput is a major roadblock to realizing printed electronics. This award supports research to advance a new printing process as a state-of-art manufacturing platform for low-cost printed devices. The recently invented printing process, which uses nanoporous stamps, can produce features with micron-scale lateral dimensions (less than 10 micrometers), fine-edge roughness (less than 1 micrometer) and highly uniform thickness in the less than 100 nanometer range, at industrial scale printing speeds (greater than 0.1 meter per second). The practical significance of advances in printed electronics and the relevance of this topic to industry partners and the NextFlex Flexible Hybrid Electronics Manufacturing Innovation Institute suggest a pathway for transition of fundamental research in printed electronics to the commercial marketplace. Therefore, this activity directly enhances the nation's prosperity and security. In addition, the project emphasizes mentorship and outreach not only to graduate and undergraduate students in research, but to broad audiences through initiatives such as promotion of nanomaterials using artistic imagery, and a new nanomanufacturing teaching module for a Massive Open Online Course (MOOC) on Fundamentals of Manufacturing Processes.The new printing process uses engineered nanoporous stamps composed of polymer coated carbon nanotube (CNT) forests, which are highly porous (90 percent), retain the ink within their volume rather than on their surfaces only, and can transfer highly uniform ink layers under mechanical contact. The project focuses on the following three main thrust areas: (1) investigation of the ink transfer mechanics and precision process control, by combination of analytical and experimental approaches; (2) roll-to-roll printing and reliability studies, wherein the nanoporous stamps are fabricated on rollers and high-speed roll-to-roll printing is studied using a desktop apparatus; and (3) demonstration of printed devices for three high-value applications that leverage the unique capabilities of nanoporous flexography process, namely quantum dot (QD) filters for imaging spectrometers, high-resolution thin-film transistors, and optical metasurfaces. Understanding from these efforts enable precision control of lateral and vertical dimensions of printed features, and scalable nanoporous stamp materials that resist both mechanical degradation and loss of print quality.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.

几个世纪以来，印刷技术的创新与沟通，教育和工业化的进步息息相关。即使数字媒体取代了很大一部分的印刷媒体，但印刷技术的进一步突破对于以新格式的电子设备的可扩展制造至关重要，例如在窗户，隐形眼镜和产品包装上。但是，无法以高吞吐量以微米级分辨率打印电子材料是实现印刷电子产品的主要障碍。该奖项支持研究，以推进新的印刷过程，作为低成本印刷设备的最先进的制造平台。最近发明的使用纳米孔邮票的印刷过程可以产生具有微米尺度横向尺寸（小于10微米），细边缘粗糙度（小于1微米）和高度均匀厚度的特征，在工业尺度打印速度（大于0.1米）下，厚度较小。印刷电子产品进展的实际意义以及该主题与行业合作伙伴的相关性以及NextFlex柔性混合电子制造创新研究所，这表明了印刷电子产品基本研究向商业市场过渡的途径。因此，这项活动直接增强了国家的繁荣和安全。此外，该项目还强调指导和宣传不仅是研究研究生和本科生的研究，而且还通过诸如促进使用艺术图像促进纳米材料的计划，以及一个新的纳米制造教学模块，用于大规模开放的在线课程（MOOC）对制造工艺的基本面。 （CNT）高度多孔（90％）的森林将墨水保留在其体积中，而不是仅在其表面上，并且可以在机械接触下传递高度均匀的墨水层。 该项目着重于以下三个主要推力区域：（1）通过结合分析和实验方法来研究墨水传输力学和精确过程控制； （2）使用台式机器研究滚动打印和可靠性研究，其中纳米方邮票是在滚筒上制造的，高速卷到滚动打印； （3）为三种高价值应用的印刷设备的演示，以利用纳米方向灵活过程的独特功能，即用于成像光谱仪，高分辨率的薄膜晶体管和光学元素的量子点（QD）滤波器。 从这些努力中理解能够精确控制印刷特征的横向和垂直尺寸，以及可扩展的纳米孔邮票材料，这些邮票材料既可以抵抗机械降解和印刷质量的丧失。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的影响审查标准来通过评估来获得支持的。

项目成果

A Microneedle Technology for Sampling and Sensing Bacteria in the Food Supply Chain

• DOI: 10.1002/adfm.202005370
• 发表时间: 2020-09-09
• 期刊: ADVANCED FUNCTIONAL MATERIALS
• 影响因子: 19
• 作者: Kim, Doyoon;Cao, Yunteng;Marelli, Benedetto
• 通讯作者: Marelli, Benedetto

Dynamics of Liquid Transfer from Nanoporous Stamps in High-Resolution Flexographic Printing

高分辨率柔版印刷中纳米孔印模的液体转移动力学

• DOI: 10.1021/acs.langmuir.9b00460
• 发表时间: 2019
• 期刊: Langmuir
• 影响因子: 3.9
• 作者: Mariappan, Dhanushkodi D.;Kim, Sanha;Boutilier, Michael S.;Zhao, Junjie;Zhao, Hangbo;Beroz, Justin;Muecke, Ulrich;Sojoudi, Hossein;Gleason, Karen;Brun, Pierre-Thomas
• 通讯作者: Brun, Pierre-Thomas

A precision desktop plate-to-roll apparatus for development of advanced flexographic printing processes

• DOI: 10.1016/j.precisioneng.2020.07.012
• 发表时间: 2020-11-01
• 期刊: PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
• 影响因子: 3.6
• 作者: Mariappan, Dhanushkodi D.;Kim, Sanha;Hart, A. John
• 通讯作者: Hart, A. John