A fully roll-to-roll gravure-printed carbon nanotube-based active matrix for multi-touch sensors.

Roll-to-roll (R2R) printing has been pursued as a commercially viable high-throughput technology to manufacture flexible, disposable, and inexpensive printed electronic devices. However, in recent years, pessimism has prevailed because of the barriers faced when attempting to fabricate and integrate thin film transistors (TFTs) using an R2R printing method. In this paper, we report 20 × 20 active matrices (AMs) based on single-walled carbon nanotubes (SWCNTs) with a resolution of 9.3 points per inch (ppi) resolution, obtained using a fully R2R gravure printing process. By using SWCNTs as the semiconducting layer and poly(ethylene terephthalate) (PET) as the substrate, we have obtained a device yield above 98%, and extracted the key scalability factors required for a feasible R2R gravure manufacturing process. Multi-touch sensor arrays were achieved by laminating a pressure sensitive rubber onto the SWCNT-TFT AM. This R2R gravure printing system overcomes the barriers associated with the registration accuracy of printing each layer and the variation of the threshold voltage (Vth). By overcoming these barriers, the R2R gravure printing method can be viable as an advanced manufacturing technology, thus enabling the high-throughput production of flexible, disposable, and human-interactive cutting-edge electronic devices based on SWCNT-TFT AMs.

Scalability of carbon-nanotube-based thin film transistors for flexible electronic devices manufactured using an all roll-to-roll gravure printing system.

To demonstrate that roll-to-roll (R2R) gravure printing is a suitable advanced manufacturing method for flexible thin film transistor (TFT)-based electronic circuits, three different nanomaterial-based inks (silver nanoparticles, BaTiO3 nanoparticles and single-walled carbon nanotubes (SWNTs)) were selected and optimized to enable the realization of fully printed SWNT-based TFTs (SWNT-TFTs) on 150-m-long rolls of 0.25-m-wide poly(ethylene terephthalate) (PET). SWNT-TFTs with 5 different channel lengths, namely, 30, 80, 130, 180, and 230 µm, were fabricated using a printing speed of 8 m/min. These SWNT-TFTs were characterized, and the obtained electrical parameters were related to major mechanical factors such as web tension, registration accuracy, impression roll pressure and printing speed to determine whether these mechanical factors were the sources of the observed device-to-device variations. By utilizing the electrical parameters from the SWNT-TFTs, a Monte Carlo simulation for a 1-bit adder circuit, as a reference, was conducted to demonstrate that functional circuits with reasonable complexity can indeed be manufactured using R2R gravure printing. The simulation results suggest that circuits with complexity, similar to the full adder circuit, can be printed with a 76% circuit yield if threshold voltage (Vth) variations of less than 30% can be maintained.

Fully printed flexible and disposable wireless cyclic voltammetry tag.

A disposable cyclic voltammetry (CV) tag is printed on a plastic film by integrating wireless power transmitter, polarized triangle wave generator, electrochemical cell and signage through a scalable gravure printing method. By proximity of 13.56 MHz RF reader, the printed CV tag generates 320 mHz of triangular sweep wave from +500 mV to -500 mV which enable to scan a printed electrochemical cell in the CV tag. By simply dropping any specimen solution on the electrochemical cell in the CV tag, the presence of solutes in the solution can be detected and shown on the signage of the CV tag in five sec. 10 mM of N,N,N',N'-tetramethyl-p-phenylenediamine (TMPD) was used as a standard solute to prove the working concept of fully printed disposable wireless CV tag. Within five seconds, we can wirelessly diagnose the presence of TMPD in the solution using the CV tag in the proximity of the 13.56 MHz RF reader. This fully printed and wirelessly operated flexible CV tag is the first of its kind and marks the path for the utilization of inexpensive and disposable wireless electrochemical sensor systems for initial diagnose hazardous chemicals and biological molecules to improve public hygiene and health.

Roll to plate printed stretchable silver electrode using single walled carbon nanotube on elastomeric substrate.

Stretchable electronics may open new applications in display, sensors and actuators. To attain the stretchable electronics, the ink formulation should be compatible with elastomeric substrates. Here, we present the formulation of silver nanoparticles and single walled carbon nanotubes (SWNTs) for printing stretchable silver electrodes on the elastomeric substrates. Highly conductive stretchable electrodes can be printed directly on the poly(styrene-b-butadiene-b-styrene) (PSBS) substrates by roll to plate (R2P) gravure printer. During the stretching test, R2P printed silver based stretchable electrodes show the high conductivity of 1000 S cm(-1) at 0.27 wt% of SWNT loading. Furthermore, the resistance of the printed silver electrode was not changed up to 15% of tensile strain.

All printed edge-triggered register using single walled carbon nanotube-based thin film transistor.

We have studied the fabrication of Single Walled Carbon Nanotube (SWNT)-based Thin Film Transistors (TFTs) using Roll-to-Roll (R2R) gravure printer and inkjet printer on PET foils to show the possibility of printed electronics in point of mass production and low cost. In this paper, for realization of all printed multi-bits digital circuit, all printed positive-edge triggered master-slave D flip-flop (DFF) was fabricated on PET foil using printed SWNT TFTs. The printed DFF, consists of 8 NAND gates and 4 inverters, exhibit propagation delay of 75 ms at the input clock signal of 5 Hz.

Fully roll-to-roll gravure printed rectenna on plastic foils for wireless power transmission at 13.56 MHz.

Wireless power transmission to inexpensive and disposable smart electronic devices is one of the key issues for the realization of a ubiquitous society where sensor networks such as RFID tags, price tags, smart logos, signage and sensors could be fully interconnected and utilized by DC power of less than 0.3 W. This DC power can be provided by inductively coupled AC from a 13.56 MHz power transmitter through a rectenna, consisting of an antenna, a diode and a capacitor, which would be cheap to integrate with inexpensive smart electronic devices. To integrate the rectenna with a minimum cost, a roll-to-roll (R2R) gravure printing process has been considered to print the rectenna on plastic foils. In this paper, R2R gravure printing systems including printing condition and four different nanoparticle based inks will be reported to print the rectenna (antenna, diode and capacitor) on plastic foils at a printing speed of 8 m min(-1) and more than 90% device yield for a wireless power transmission of 0.3 W using a standard 13.56 MHz power transmitter.

AM radio circuit using printed electronic components.

In this paper, printing technologies have been employed to print the resonant circuit and detection circuit for an amplitude modulation system (AM radio), which consists of a printed inductor, capacitor, resistor and diode on plastic foils for using as an AM radio circuit. To test the printed inductor, capacitor, resistor and diode as components of AM radio, we selected 640 KHz, the strongest AM frequency in Sunchon City, Korea and monitored the audio signal by replacing each component by a corresponding printed one. As a result the 640 KHz AM radio signals were detected.