Surface Wrinkle Roll-to-Roll Manufacturing With Curvature-Induced Strain
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Solution Overview
Problem
Conventional methods for manufacturing micro/nano-scale wrinkles are not suitable for large-scale, continuous production, limiting the commercialization of surface wrinkle-related technologies.
Innovation Solution
A scalable roll-to-roll manufacturing method using curvature-induced strains on a cylindrical support to produce surface wrinkles, employing UV-curable polydimethylsiloxane (PDMS) and oxygen plasma treatment to generate one-dimensional and two-dimensional patterns, enabling continuous production of wrinkled materials with controlled wavelengths and amplitudes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional batch processes are used for wrinkle fabrication, then manufacturing precision can be maintained, but productivity is severely limited and not suitable for large-scale production
Solution Approach 1:
The patent implements a continuous roll-to-roll manufacturing process where substrates are continuously fed through curing and wrinkling zones. The conveyor system maintains continuous motion, allowing uninterrupted production of wrinkled surfaces at industrial scale, directly resolving the productivity limitation of batch processes
Solution Approach 2:
The patent employs cylindrical drums with controlled curvature to induce wrinkles on the substrate surface. By adjusting the drum radius and substrate tension, specific wrinkle patterns and wavelengths are generated continuously as the substrate passes over the drums, enabling scalable production while maintaining manufacturing precision
2Productivity
If manual piece-by-piece fabrication methods are used, then manufacturing precision is achievable, but the process is not amenable to scale-up for commercialization
Solution Approach 1:
The patent controls wrinkle characteristics by adjusting process parameters including substrate tension, conveyor speed, drum curvature radius, and curing temperature. These parameter variations enable precise control of wrinkle wavelength and amplitude while maintaining continuous high-volume production suitable for commercialization
Solution Approach 2:
The patent replaces manual mechanical fabrication with an automated system combining UV curing, controlled substrate tensioning, and cylindrical drum contact. This mechanical-optical system achieves consistent wrinkle patterns across large production volumes without manual intervention, enabling commercial-scale manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the efficient and scalable production of surface wrinkles with controlled features, enhancing light harvesting efficiency in solar cells and enabling applications in stretchable electronics and tunable optics.
Implementation Method 1
a bending strain was introduced to a thin layer of ultraviolet (UV)-curable polydimethylsiloxane (UV-PDMS) coated on top of a soft PDMS substrate by wrapping the bilayer around a cylindrical roller. After curing the UV-PDMS
Implementation Method 2
a bending strain was introduced to a thin layer of ultraviolet (UV)-curable polydimethylsiloxane (UV-PDMS) coated on top of a soft PDMS substrate by wrapping the bilayer around a cylindrical roller
Implementation Method 3
After curing the UV-PDMS and subsequently releasing the bending strain, one-dimensional or checkerboard surface wrinkles were produced
Implementation Method 4
employing UV-curable polydimethylsiloxane (PDMS) and oxygen plasma treatment to generate one-dimensional and two-dimensional patterns
Data Source
AI summary
Provided are systems and methods for inducing strain fields to give rise to controllable wrinkle patterns in a variety of substrates. Also provided are articles having persistent wrinkling patterns thereon.