WO2018079927A1 - Apparatus and method for manufacturing a flexible film - Google Patents

Apparatus and method for manufacturing a flexible film Download PDF

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Publication number
WO2018079927A1
WO2018079927A1 PCT/KR2016/014460 KR2016014460W WO2018079927A1 WO 2018079927 A1 WO2018079927 A1 WO 2018079927A1 KR 2016014460 W KR2016014460 W KR 2016014460W WO 2018079927 A1 WO2018079927 A1 WO 2018079927A1
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WO
WIPO (PCT)
Prior art keywords
base film
intaglio
groove
manufacturing
control unit
Prior art date
Application number
PCT/KR2016/014460
Other languages
French (fr)
Inventor
Joong Kook Hwang
Original Assignee
Protem Co., Ltd.
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Filing date
Publication date
Application filed by Protem Co., Ltd. filed Critical Protem Co., Ltd.
Publication of WO2018079927A1 publication Critical patent/WO2018079927A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/12—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a coating with specific electrical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
    • B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/026—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing of layered or coated substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/52—Electrically conductive inks
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/24—Electrically-conducting paints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C2037/0046—In-mould printing, in-mould transfer printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0077—Yield strength; Tensile strength

Definitions

  • the present disclosure relates to an apparatus and a method for manufacturing a flexible film. More particularly, the present disclosure relates to an apparatus and a method for manufacturing a flexible film for forming a pattern and coating on a stretched film material.
  • an intaglio pattern is formed through an imprint process using a mold formed with a micro pattern, a groove of a patterned intaglio is filled with a conductive material, and the conductive residues except the imprinted part are removed by mechanical abrasion in the Korean Patent No. 0957487.
  • a conventional problem in a conventional manufacturing method by a single process of flat, engraving pattern is that a transparent electrode is caused to be ruptured in extreme bending conditions (for example, when the radius of curvature is 1mm).
  • the purpose of the present disclosure is to provide an apparatus and a method for manufacturing a flexible film which has super-high flexibility and superior low-resistance characteristic by adding an engraving method with a constant stress applied during the process of coating a base film in manufacturing a transparent electrode film, which is derived by considering the aforementioned problems.
  • the apparatus for manufacturing a flexible film may include a stretching unit 100 for pulling a base film to maintain a constant tensile strength; a pattern forming unit 200 for forming a groove of an intaglio on a top surface of the pulled base film by using a mold with an embossed pattern; a filling unit 300 for filling the groove of the intaglio with a conductive solution and performing cleaning; a coating head 400 for coating the conductive solution with which the groove of the intaglio is filled.
  • the stretching unit functions to maintain a constant tensile strength at a yield point of an elastic limit according to a material quality of the base film by a stress applied to the heated base film.
  • the base film is any one of PET, PI, PDMS, and PU series.
  • the pattern forming unit 200 may form a groove of an intaglio on a top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
  • a manufacturing method by using the apparatus for manufacturing a flexible film may include (a) maintaining a constant tensile strength by pulling a base film by the control unit of the apparatus pulling the base film; (b) forming a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern by the control unit; (c) filling the groove of the intaglio with the conductive solution by the control unit; (d) cleaning the rest part except the groove of the intaglio on the pulled base film by the control unit; and (e) coating the conductive solution on the pulled film filled with the conductive solution by the control unit.
  • inflexibility of a ITO material used for a transparent electrode is overcome and stability under extreme bending conditions is attained by using a nano material and a nano technology in the present disclosure, super high flexibility and superior low resistance characteristic are acquired.
  • the present disclosure can be applied to a touch panel, a flat panel, a solar battery, a vehicle-mounted transparent heating element, a transparent electromagnetic wave shield, etc. in the overall industry.
  • FIG. 1 is a diagram of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 2 illustrates the concept of a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 3 illustrates a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 4 illustrates sequential control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 5 illustrates other control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 6 is an overall flow chart of a manufacturing method using an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • an apparatus and a method for manufacturing a flexible film according to an exemplary embodiment of the present invention can prevent rupture in the extreme bending condition (1mm), when manufacturing a transparent electrode film, by adding a temperature, an engraving method in the process for coating a base film with a constant stress applied.
  • FIG. 1 is a diagram of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • the apparatus may include a stretching unit 100, a pattern forming unit 200, a filling unit 300, a coating head 400, and a control unit 500.
  • FIG. 2 illustrates the concept of a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • the stretching unit 100 is provided to maintain a constant tensile strength by pulling a heated base film.
  • the stretching unit 100 is configured to maintain a constant tensile strength at the elastic limit yield point according to the material quality of a base film.
  • the base film according to exemplary embodiments of the present invention may be any one among PET, PI, PDMS, PU series.
  • the stretching unit 100 is configured to maintain a constant stress at an elastic limit yield point.
  • the elastic limit yield point means the stress before causing a permanent deformation, and the original state is restored when the applied stress is removed.
  • a yield point depends on a material quality of a film.
  • a film is configured to be pulled by a constant stress before reaching a yield point before a permanent deformation according to a material quality of a film.
  • FIG. 3 illustrates a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • a connecting means 2 of the stretching unit 100 is connected and fixed to each end of a base film 1 and can be pulled with a constant stress to maintain a constant tensile strength at an elastic limit yield point which is determined according to a material quality of the corresponding base film.
  • the fixed connection may be provided by considering an elastic limit yield point and applying a constant stress.
  • the fixed connection may be pulled by an elastic member such as a spring to apply stress.
  • the stretching unit 100 may pull a heated base film or a base film simultaneously with heating to maintain a constant stress.
  • a pattern forming unit 200 is configured to form a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern.
  • the pattern forming unit 200 may form a groove of an intaglio on the top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
  • a filling unit 300 is configured to fill the intaglio with a conductive solution and perform cleaning.
  • the intaglio is filled with a conductive solution by doctor blade coater, and the conductive solution may be any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
  • a coating head 400 is configured to coat the conductive solution with which the groove of the intaglio has been filled.
  • the coating head 400 is configured to coat the conductive solution on the pulled base film by any method of Slot die or Micro-gravure or Comma method.
  • a control unit 500 is provided to control the stretching unit 100, the pattern forming unit 200, the filling unit 300, the coating head 400. And the pulled film may go back to the original state by drying the base film coated by the coating head 400 and releasing the stress applied to the stretching unit 100.
  • FIG. 4 illustrates sequential control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • FIG. 5 illustrates other control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • the control unit may control performing the operation of the pattern forming unit 200 on the upper part of the stretching unit 100 moving on a rail, and the sequential operations of the filling unit 300 and the coating head 400.
  • the pattern forming unit 200 may perform its action first for the fixed stretching unit 100 and move to another location before the filling unit 300 and the coating head 400 are moved to perform the operations.
  • the manufacturing method using the apparatus for manufacturing a flexible film according to the operation of the control unit is described as in the following.
  • FIG. 6 is an overall flow chart of a manufacturing method using an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
  • the control unit operates for maintaining a constant tensile strength by pulling a base film(a).
  • the stress applied to the heated base film is provided to maintain the constant tensile strength at an elastic limit yield point according to a material quality of the base film.
  • control unit operates for forming a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern(b).
  • control unit may operate to form a groove of an intaglio on the top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
  • the control unit operates for filling the groove of the intaglio with a conductive solution(c).
  • the method for filling the groove of the intaglio with a conductive solution is filling by doctor blade coater, and a conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
  • control unit operates for cleaning the rest part except the groove of the intaglio on the pulled base film(d).
  • control unit may operate for coating the conductive solution on the pulled film filled with the conductive solution by Slot die or Micro-gravure or Comma method(e).
  • control unit may control the stretching unit to loosen the tensile strength of the stretching unit back to the original state.
  • control unit according to the present exemplary embodiment as illustrated in FIG. 4 has the groove of the intaglio formed by the mold with the embossed pattern of the pattern forming unit 200 on the top surface of the base film which is pulled on the rail.
  • the groove of the intaglio is filled with a conductive resolution.
  • the groove of the intaglio is filled with a conductive resolution by doctor blade coater, and the conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
  • the stretching unit of the film pulled on the rail is moved to clean the rest part except the groove of the intaglio.
  • a coating head 400 for coating the conductive solution on the film filled with the conductive solution in Slot die or Micro-gravure or Comma method by doctor blade coater may be performed sequentially. That is, in the method according to the exemplary embodiment of FIG.4, the pulled film is sequentially moved on the rail to perform each process.
  • the pattern forming unit 200 performs its operation first. Then, the mold with the embossed pattern is moved to another location.
  • the groove of the intaglio is filled with the conductive solution and then cleaning is performed.
  • the coating head 400 for coating the conductive solution on the film may be moved to the upper side of the pulled film to perform a coating head action by Slot die or Microgravure or Comma method.
  • the method illustrated in FIG. 5 may include stopping the pulled film on the moving rail, forming a pattern and filling with a conductive solution, performing cleaning. having the coating head moved to the upper side of the pulled film for sequential operations, and then moving the stopped film on the rail.
  • the apparatus and the method for manufacturing a flexible film according to the present disclosure the inflexibility of a ITO material used for transparent electrodes is overcome, and super high flexibility and superior low resistance characteristic are obtained by using a nano material and a nano technology for attaining stability under extreme bending conditions in the present disclosure.
  • non-folderable, non-stretchable, non-flexible problems due to the biggest weak point of conventional ITO i.e. the limit of bending and stretch ability can be solved.
  • the present disclosure can be applied to a touch panel, a flat display, a solar battery, a vehicle-mounted transparent heating element, a transparent electromagnetic wave shield, etc. in the overall industry.

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Abstract

Disclosed herein are an apparatus and a method for manufacturing a flexible film. more particularly an apparatus and a method for manufacturing a flexible film for forming a pattern and coating on a stretched film material. According to the present disclosure, inflexibility of ITO materials used for a conventional transparent electrode is overcome, and super high flexibility and superior low-resistance characteristic are acquired by using a nano material and a nano technology for attaining stability under extreme bending conditions

Description

APPARATUS AND METHOD FOR MANUFACTURING A FLEXIBLE FILM
The present disclosure relates to an apparatus and a method for manufacturing a flexible film. More particularly, the present disclosure relates to an apparatus and a method for manufacturing a flexible film for forming a pattern and coating on a stretched film material.
In a conventional method for manufacturing a plastic electrode film, an intaglio pattern is formed through an imprint process using a mold formed with a micro pattern, a groove of a patterned intaglio is filled with a conductive material, and the conductive residues except the imprinted part are removed by mechanical abrasion in the Korean Patent No. 0957487.
A conventional problem in a conventional manufacturing method by a single process of flat, engraving pattern is that a transparent electrode is caused to be ruptured in extreme bending conditions (for example, when the radius of curvature is 1mm).
The purpose of the present disclosure is to provide an apparatus and a method for manufacturing a flexible film which has super-high flexibility and superior low-resistance characteristic by adding an engraving method with a constant stress applied during the process of coating a base film in manufacturing a transparent electrode film, which is derived by considering the aforementioned problems.
The apparatus for manufacturing a flexible film may include a stretching unit 100 for pulling a base film to maintain a constant tensile strength; a pattern forming unit 200 for forming a groove of an intaglio on a top surface of the pulled base film by using a mold with an embossed pattern; a filling unit 300 for filling the groove of the intaglio with a conductive solution and performing cleaning; a coating head 400 for coating the conductive solution with which the groove of the intaglio is filled.
Preferably, the stretching unit functions to maintain a constant tensile strength at a yield point of an elastic limit according to a material quality of the base film by a stress applied to the heated base film.
In addition, the base film is any one of PET, PI, PDMS, and PU series.
In addition, the pattern forming unit 200 may form a groove of an intaglio on a top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
Meanwhile, a manufacturing method by using the apparatus for manufacturing a flexible film may include (a) maintaining a constant tensile strength by pulling a base film by the control unit of the apparatus pulling the base film; (b) forming a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern by the control unit; (c) filling the groove of the intaglio with the conductive solution by the control unit; (d) cleaning the rest part except the groove of the intaglio on the pulled base film by the control unit; and (e) coating the conductive solution on the pulled film filled with the conductive solution by the control unit.
As aforementioned, inflexibility of a ITO material used for a transparent electrode is overcome and stability under extreme bending conditions is attained by using a nano material and a nano technology in the present disclosure, super high flexibility and superior low resistance characteristic are acquired.
In addition, non-folderable, non-stretchable, and non-flexible problems due to the biggest weak point of conventional ITO i.e. the limit of bending and stretch ability can be overcome. Thus, the present disclosure can be applied to a touch panel, a flat panel, a solar battery, a vehicle-mounted transparent heating element, a transparent electromagnetic wave shield, etc. in the overall industry.
FIG. 1 is a diagram of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 2 illustrates the concept of a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 3 illustrates a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 4 illustrates sequential control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 5 illustrates other control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 6 is an overall flow chart of a manufacturing method using an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
The present invention will be described more fully hereinafter with reference to the accompanying drawings. In the following description of the embodiments of the present invention, when the well-known technology and the specific description about its configuration related to the present invention are determined to unnecessarily obscure the subject matter of the present invention, they will be omitted.
First, an apparatus and a method for manufacturing a flexible film according to an exemplary embodiment of the present invention can prevent rupture in the extreme bending condition (1mm), when manufacturing a transparent electrode film, by adding a temperature, an engraving method in the process for coating a base film with a constant stress applied.
And each process is operated at the elastic limit yield point of a film, thus the stability can be guaranteed in the extreme bending conditions.
FIG. 1 is a diagram of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention. As illustrated in FIG. 1, the apparatus may include a stretching unit 100, a pattern forming unit 200, a filling unit 300, a coating head 400, and a control unit 500.
FIG. 2 illustrates the concept of a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
The stretching unit 100, as illustrated in FIG. 2, is provided to maintain a constant tensile strength by pulling a heated base film. The stretching unit 100 is configured to maintain a constant tensile strength at the elastic limit yield point according to the material quality of a base film.
The base film according to exemplary embodiments of the present invention may be any one among PET, PI, PDMS, PU series.
When deforming an object by applying stress to it, in case the stress is small, the object is deformed (elastic deformation)in proportion to the increase in stress. And when the stress is removed, the object goes back to the original state. However, a drastic deformation may occur when the stress exceeds a certain limit. This is called a yield and the limit stress is called a yield stress of the material or just a yield value or a yield point. When the stress exceeds the yield stress, the permanent deformation remains even after removing the stress.
The stretching unit 100 according to an exemplary embodiment of the present invention is configured to maintain a constant stress at an elastic limit yield point. At this time, the elastic limit yield point means the stress before causing a permanent deformation, and the original state is restored when the applied stress is removed.
That is, a yield point depends on a material quality of a film. A film is configured to be pulled by a constant stress before reaching a yield point before a permanent deformation according to a material quality of a film.
FIG. 3 illustrates a stretching unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
When a constant stress is maintained by pulling the heated base film as illustrated in FIG. 3, a connecting means 2 of the stretching unit 100 is connected and fixed to each end of a base film 1 and can be pulled with a constant stress to maintain a constant tensile strength at an elastic limit yield point which is determined according to a material quality of the corresponding base film.
At this time, even when the base film is connected and fixed to the stretching unit, the fixed connection may be provided by considering an elastic limit yield point and applying a constant stress. The fixed connection may be pulled by an elastic member such as a spring to apply stress.
And the stretching unit 100 may pull a heated base film or a base film simultaneously with heating to maintain a constant stress.
A pattern forming unit 200 is configured to form a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern.
The pattern forming unit 200 may form a groove of an intaglio on the top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
A filling unit 300 is configured to fill the intaglio with a conductive solution and perform cleaning. At this time, the intaglio is filled with a conductive solution by doctor blade coater, and the conductive solution may be any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
A coating head 400 is configured to coat the conductive solution with which the groove of the intaglio has been filled. The coating head 400 is configured to coat the conductive solution on the pulled base film by any method of Slot die or Micro-gravure or Comma method.
A control unit 500 is provided to control the stretching unit 100, the pattern forming unit 200, the filling unit 300, the coating head 400. And the pulled film may go back to the original state by drying the base film coated by the coating head 400 and releasing the stress applied to the stretching unit 100.
FIG. 4 illustrates sequential control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
FIG. 5 illustrates other control operations of a control unit of an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
The control unit, as illustrated in FIG. 4, may control performing the operation of the pattern forming unit 200 on the upper part of the stretching unit 100 moving on a rail, and the sequential operations of the filling unit 300 and the coating head 400. As illustrated in FIG. 5, the pattern forming unit 200 may perform its action first for the fixed stretching unit 100 and move to another location before the filling unit 300 and the coating head 400 are moved to perform the operations.
The manufacturing method using the apparatus for manufacturing a flexible film according to the operation of the control unit is described as in the following.
FIG. 6 is an overall flow chart of a manufacturing method using an apparatus for manufacturing a flexible film according to an exemplary embodiment of the present invention.
The manufacturing method using the apparatus for manufacturing a flexible film is described as in the following with reference to FIG. 6.
As illustrated in FIG. 6, the control unit operates for maintaining a constant tensile strength by pulling a base film(a). Here, by the step (a), the stress applied to the heated base film is provided to maintain the constant tensile strength at an elastic limit yield point according to a material quality of the base film.
Next, the control unit operates for forming a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern(b). Here, the control unit may operate to form a groove of an intaglio on the top surface of the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
Next, the control unit operates for filling the groove of the intaglio with a conductive solution(c). At this time, the method for filling the groove of the intaglio with a conductive solution is filling by doctor blade coater, and a conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
Next, the control unit operates for cleaning the rest part except the groove of the intaglio on the pulled base film(d).
Next, the control unit may operate for coating the conductive solution on the pulled film filled with the conductive solution by Slot die or Micro-gravure or Comma method(e).
And when drying the coated film in the pulled state is completed, the control unit may control the stretching unit to loosen the tensile strength of the stretching unit back to the original state.
As aforementioned, the control unit according to the present exemplary embodiment as illustrated in FIG. 4 has the groove of the intaglio formed by the mold with the embossed pattern of the pattern forming unit 200 on the top surface of the base film which is pulled on the rail.
Next, the groove of the intaglio is filled with a conductive resolution. At this time, the groove of the intaglio is filled with a conductive resolution by doctor blade coater, and the conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT, etc.
Next, the stretching unit of the film pulled on the rail is moved to clean the rest part except the groove of the intaglio.
Next, the actions of a coating head 400 for coating the conductive solution on the film filled with the conductive solution in Slot die or Micro-gravure or Comma method by doctor blade coater may be performed sequentially. That is, in the method according to the exemplary embodiment of FIG.4, the pulled film is sequentially moved on the rail to perform each process.
In addition, as illustrated in FIG. 5, when the stretching unit 100 stops on the rail, the pattern forming unit 200 performs its operation first. Then, the mold with the embossed pattern is moved to another location.
Next, the groove of the intaglio is filled with the conductive solution and then cleaning is performed.
Next, the coating head 400 for coating the conductive solution on the film may be moved to the upper side of the pulled film to perform a coating head action by Slot die or Microgravure or Comma method.
Thus, the method illustrated in FIG. 5, may include stopping the pulled film on the moving rail, forming a pattern and filling with a conductive solution, performing cleaning. having the coating head moved to the upper side of the pulled film for sequential operations, and then moving the stopped film on the rail.
By the apparatus and the method for manufacturing a flexible film according to the present disclosure, the inflexibility of a ITO material used for transparent electrodes is overcome, and super high flexibility and superior low resistance characteristic are obtained by using a nano material and a nano technology for attaining stability under extreme bending conditions in the present disclosure.
In addition, non-folderable, non-stretchable, non-flexible problems due to the biggest weak point of conventional ITO i.e. the limit of bending and stretch ability can be solved. Thus, the present disclosure can be applied to a touch panel, a flat display, a solar battery, a vehicle-mounted transparent heating element, a transparent electromagnetic wave shield, etc. in the overall industry.

Claims (9)

  1. An apparatus for manufacturing a flexible film, comprising:
    a stretching unit 100 for pulling a base film to maintain a constant tensile strength;
    a pattern forming unit 200 for forming a groove of an intaglio on the pulled base film by using a mold with an embossed pattern;
    a filling unit 300 for filling the groove of the intaglio with a conductive solution and cleaning; and
    a coating head 400 for coating the conductive solution with which the groove of the intaglio has been filled.
  2. The apparatus of claim 1, wherein the stretching unit 100 functions such that a stress applied to a heated base film maintains a constant tensile strength at a yield point of an elastic limit according to a material quality of the base film.
  3. The apparatus of claim 1, wherein the base film is any one of PET, PI, PDMS, and PU series.
  4. The apparatus of claim 1, wherein the pattern forming unit 200 forms a groove of an intaglio on the pulled base film through a hot embossing or an imprinting by using a mold with an embossed pattern.
  5. The apparatus of claim 1, wherein the conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT.
  6. A method for manufacturing a flexible film by using an apparatus for manufacturing a flexible film, comprising:
    (a) maintaining a constant tensile strength by pulling a base film by a control unit of the apparatus;
    (b) forming a groove of an intaglio on the top surface of the pulled base film by using a mold with an embossed pattern by the control unit;
    (c) filling the groove of the intaglio with a conductive solution by the control unit;
    (d) cleaning the rest part except the groove of the intaglio on the pulled base film by the control unit; and
    (e) coating the conductive solution on the pulled film filled with the conductive solution by the control unit.
  7. The method of claim 6, wherein the step (a) is maintaining a constant tensile strength at an elastic limit yield point according to a material quality of the base film by the stress applied to the heated base film by the control unit.
  8. The method of claim 6, wherein the step (b) is forming a groove of an intaglio on the top surface of the pulled base film through a hot embossing or an imprinting by using a mold with embossed pattern by the control unit.
  9. The method of claim 6, wherein the conductive solution is any one of Ag paste, AgNW, Copper, Ni, CNT, Graphene, PEDOT.
PCT/KR2016/014460 2016-10-26 2016-12-09 Apparatus and method for manufacturing a flexible film WO2018079927A1 (en)

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KR20180045596A (en) 2018-05-04

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