EEA Grants Norway Grants Comparison of three common

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EEA Grants Norway Grants Comparison of three common deposition techniques: v. Spin-coating v. Dip-coating

EEA Grants Norway Grants Comparison of three common deposition techniques: v. Spin-coating v. Dip-coating v. Material printing Ing. Marcela Králová Ph. D. , CEITEC 21. 4. 2015

Content • Principle of spin-coating • Principle of dip-coating • Different technique of material

Content • Principle of spin-coating • Principle of dip-coating • Different technique of material printing • Advantage and disadvantage of material printing • Applications

Principle of spin-coating • Principle: • Substrate is coated by ink • Substrate is

Principle of spin-coating • Principle: • Substrate is coated by ink • Substrate is rotated (majority of the ink is flung off the side) • Drying the substrate by airflow • Creation of desired layers

Principle of spin-coating

Principle of spin-coating

Principle of spin-coating • Parameters: • Thickness: nm – mm • Speed: more than

Principle of spin-coating • Parameters: • Thickness: nm – mm • Speed: more than 600 RPM (10 rotations per second) • Ink: photoresist, insulator, organic, inorganic material • Advantages: • Quickly and easily produce uniform film • Coating of small (mm) or large substrate (dm) • Disadvantages: • Low usage of materials (10%)

Principle of dip-coating • Principle: • Dip a substrate into dip coating liquid •

Principle of dip-coating • Principle: • Dip a substrate into dip coating liquid • Wait for a liquid surface to become the stationary state • Raise the substrate up perpendicularly • Control film thickness

Principle of dip-coating

Principle of dip-coating

Principle of dip-coating • Parameters: • Thickness increases withdrawal speed • Depends on viscosity,

Principle of dip-coating • Parameters: • Thickness increases withdrawal speed • Depends on viscosity, density and surface tension of liquid • Advantages: • Easy and simple maintenance • Lower loss of coat liquid than in spin-coating • Disadvantages: • Deposition of both sides • Precise control and clean environment

Material printing Classical Digital Offset Gravure Electrography Screen Relief Ink-jet

Material printing Classical Digital Offset Gravure Electrography Screen Relief Ink-jet

Offset printing • Principle: • Applying dampening solutin on the printing plate • Applying

Offset printing • Principle: • Applying dampening solutin on the printing plate • Applying ink on the printing plate • Ink transfer from printing plate to the blanket cylinder • Ink transfer from blanket cylinder to substrate

Offset printing

Offset printing

Offset printing • Printing plate (printing and non-printing areas in same level) • Printing

Offset printing • Printing plate (printing and non-printing areas in same level) • Printing areas – hydrophobic • Non-printing areas – hydrophilic • Dampening solution – water + additives

Offset printing • Ink transfer is affected by: • The thickness of ink layer

Offset printing • Ink transfer is affected by: • The thickness of ink layer on the printing plate • The period of contact (printing speed and geometry of the printing components) • The printing pressure • The rheological properties of ink • The temperature (on rheological properties) • The surface properties (wettability, absorbency, roughness…)

Offset printing possible construction • • Three transfer cylinders Possible reverse printing Three cylinder

Offset printing possible construction • • Three transfer cylinders Possible reverse printing Three cylinder units Diameter of impression cylinder is same with others

Offset printing possible construction • • One transfer cylinder Impossible reverse printing Three cylinder

Offset printing possible construction • • One transfer cylinder Impossible reverse printing Three cylinder units Diameter of impression cylinder 2 x than the other

Offset printing possible construction • • One transfer cylinder Impossible reverse printing Five cylinder

Offset printing possible construction • • One transfer cylinder Impossible reverse printing Five cylinder units Diameter of impression cylinder 4 x than the other

Gravure printing • Principle: • Printing plate is inked and flooded with ink •

Gravure printing • Principle: • Printing plate is inked and flooded with ink • Ink is removed by a wiper of blade • Transport of ink onto the substrate • Image elements are engraved into the surface of the cylinder • Non-image areas – at constant level • High printing pressure • Adhesive forces between printing substrate and ink

Gravure printing

Gravure printing

Gravure printing • Ink transfer is affected by: • The wetting properties of the

Gravure printing • Ink transfer is affected by: • The wetting properties of the printing substrate • The surface properties of the materials involved • The properties of the substrate • The viscosity of the ink • The printing pressure • The printing speed • The shape of the cells and their filling level

Relief - Letterpress • Principle: • Printing elements are coated with ink (constant thickness)

Relief - Letterpress • Principle: • Printing elements are coated with ink (constant thickness) • Transfer ink onto the substrate • Printing elements are raised above the non printing elements • Book printing • Flexographic printing • Letterset

Relief - Letterpress

Relief - Letterpress

Relief - Letterpress • Ink transfer is affected by: • The thickness of ink

Relief - Letterpress • Ink transfer is affected by: • The thickness of ink layer on the printing plate • The period of contact (printing speed and geometry of the printing components) • The printing pressure • The rheological properties of ink • The temperature (on rheological properties) • The surface properties (wettability, absorbency, roughness…)

Letterpress - Book printing • The oldest printing technique (Gutenberg) • Two cylinders system

Letterpress - Book printing • The oldest printing technique (Gutenberg) • Two cylinders system and direct printing (unreadable text) • Raised printing elements (40 – 400 mm; selectivity of ink transfer) • Plate is hard and uncompressible • High pressure (MPa) • Highly viscous, pasty ink • Smooth substrate

Letterpress – Book printing

Letterpress – Book printing

Letterpress – Book printing • Disadvantage (comparison with offset) • Expensive printing plate •

Letterpress – Book printing • Disadvantage (comparison with offset) • Expensive printing plate • Costly preparation of the printing plate • Limited print quality • Limit of production speed

Letterpress – Book printing • Operation for the creating of printing plate • Removal

Letterpress – Book printing • Operation for the creating of printing plate • Removal of the protective film • Exposure through a negative film • Washing of non-crosslinking photopolymer • Drying of print relief • Complete polymerization of the print relief

Letterpress – flexographic printing • Known from 1950 (previously as aniline printing) • Soft,

Letterpress – flexographic printing • Known from 1950 (previously as aniline printing) • Soft, flexible elements • Low pressure • Ink with low viscosity (possible to print on a wide range of absorbent and non-absorbent substrates) • Substrate (rough surface)

Letterpress – flexographic printing • Principle: • Ink transfer to anilox roller • Ink

Letterpress – flexographic printing • Principle: • Ink transfer to anilox roller • Ink transfer from anilox roller to printing plate • Ink transfer onto the substrate

Letterpress – flexographic printing

Letterpress – flexographic printing

Letterpress – flexographic printing • Disadvantage (comparison with offset): • Quality is lower •

Letterpress – flexographic printing • Disadvantage (comparison with offset): • Quality is lower • 48 lines/cm (flexography) • 60 -120 lines/cm (offset) offset flexography

Letterpress – lettreset • Principle: • Ink transferred to an intermediate cylinder covered with

Letterpress – lettreset • Principle: • Ink transferred to an intermediate cylinder covered with the blanket • Ink transfer from intermediate cylinder to substrate • Indirect process as well as offset

Screen printing • Push-through process (special type of stencil printing) • Stencil is fastened

Screen printing • Push-through process (special type of stencil printing) • Stencil is fastened onto the surface • Ink can be applied • with a brush or squeegee • with a spraygun or an airbrush • Different substrates and inks • Disadvantage: • Part must to be connected

Screen printing

Screen printing

Screen printing • Spread of ink by a squeegee (without pressure) • Ink is

Screen printing • Spread of ink by a squeegee (without pressure) • Ink is pressed through the plate with a higher pressure • Separation of plate and substrate • Ink is drawn out of the screen mesh • Applications (artistic, large-scale, …) • 3 methods: • Flat to flat • Flat to round • Round to round

Screen printing • Flat to flat: • Flat printing plate • Flat printing substrate

Screen printing • Flat to flat: • Flat printing plate • Flat printing substrate

Screen printing • Flat to round: • Flat printing plate • Round printing substrate

Screen printing • Flat to round: • Flat printing plate • Round printing substrate • Printing plate and impression cylinder move in one direction • Printing on cans, balls…

Screen printing • Round to round: • Round printing plate • Round substrate •

Screen printing • Round to round: • Round printing plate • Round substrate • Synchronized movement

Ink-jet printing • Non-impact printing technology • Ink is sprayed from nozzle • Imaging

Ink-jet printing • Non-impact printing technology • Ink is sprayed from nozzle • Imaging is done directly onto the substrate • Characteristics: • Droplet volume: 2– 160 p. L • Spatial frequency of droplets adjusting: 70 -2500 dpi • Temporal frequency of droplets formation: dozens – hundred k. Hz • Printing of whole surface: • Stationary nozzles and substrate movement • Nozzle movement across the substrate and simultaneously substrate movement

Ink-jet printing

Ink-jet printing

Ink-jet printing - inks

Ink-jet printing - inks

Ink-jet printing-continuous • Binary deflection (two charges) • • Uncharged droplets (reach the paper)

Ink-jet printing-continuous • Binary deflection (two charges) • • Uncharged droplets (reach the paper) Charged drops(deflected and fed to a collection device) • Drop size and interval depend on: • • • Nozzle diameter Viscosity and surface tension of ink Frequency of excitation • The quality depends on: • Quality and continuity of drop stream • • Parameters: • • Frequency (1 MHz) Drop size (4 p. L) Drop diameter (20 m. L) Drop speed (40 m/s)

Ink-jet printing-continuous

Ink-jet printing-continuous

Ink-jet printing-continuous • Multi deflection (different charge) • Different intensity of charge – different

Ink-jet printing-continuous • Multi deflection (different charge) • Different intensity of charge – different deflection • Jet can be deflected in 16 positions • Height of tha written line depends on the distance between ink jet head and the paper surface • Resolution is reduced with increasing writting height • Resolution is determined by • • Speed of the substrate Drop frequency • Maximum resolution is 7 x 6 dots (hxw)

Ink-jet printing-continuous

Ink-jet printing-continuous

Ink-jet printing-drop on demand • Thermal ink-jet process (bubble jet)

Ink-jet printing-drop on demand • Thermal ink-jet process (bubble jet)

Ink-jet printing-drop on demand Time sequence for drop formation

Ink-jet printing-drop on demand Time sequence for drop formation

Ink-jet printing-drop on demand • Thermal ink-jet process (bubble jet) • Parameters: • Drop

Ink-jet printing-drop on demand • Thermal ink-jet process (bubble jet) • Parameters: • Drop volume: 23 p. L • Drop diameter: 35 mm • Drop frequency: 5 -8 k. Hz • Resulition: 600 dpi

Ink-jet printing-drop on demand • Piezo ink-jet process (mechanical displacement)

Ink-jet printing-drop on demand • Piezo ink-jet process (mechanical displacement)

Ink-jet printing-drop on demand Rear wall Channel wall Rear wall

Ink-jet printing-drop on demand Rear wall Channel wall Rear wall

Ink-jet printing-drop on demand • Electrostatic ink-jet process

Ink-jet printing-drop on demand • Electrostatic ink-jet process

Ink-jet printing-drop on demand Drop generation Drop formation

Ink-jet printing-drop on demand Drop generation Drop formation

Comparison Spin Dip Inkjet Precursor use efficiency 95% wasted Coated area cm dm (m)

Comparison Spin Dip Inkjet Precursor use efficiency 95% wasted Coated area cm dm (m) Sensitivity to surface defects high low Possibility of patterning none unlimited

Applications • Office printer • Since 2005: Epson printers • Modified CD holder •

Applications • Office printer • Since 2005: Epson printers • Modified CD holder • Experimental printer • Since 2009: Inkjet deposition printer Fujifilm Dimatix

Applications • Example of printed structure • Photocatalysts layers patterns • Sensors electrodes +

Applications • Example of printed structure • Photocatalysts layers patterns • Sensors electrodes + active layers • Solar cells

Applications - office printer • Liquid precursor • Substrate: glass or pyrex plates

Applications - office printer • Liquid precursor • Substrate: glass or pyrex plates

Applications - experimental printer • Liquid precursor • Substrate: glass, pyrex plates, foils,

Applications - experimental printer • Liquid precursor • Substrate: glass, pyrex plates, foils,

Thank you for your attention • This project is funded by the Norwegian Financial

Thank you for your attention • This project is funded by the Norwegian Financial Mechanism. Registration number: NF-CZ 07 -ICP-1 -040 -2014. Name of the project: „Formation of research surrounding for young researchers in the field of advanced materials for catalysis and bioapplications“