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result(s) for
"roll-to-roll"
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Structurally Colored Radiative Cooling Cellulosic Films
2022
Daytime radiative cooling (DRC) materials offer a sustainable approach to thermal management by exploiting net positive heat transfer to deep space. While such materials typically have a white or mirror‐like appearance to maximize solar reflection, extending the palette of available colors is required to promote their real‐world utilization. However, the incorporation of conventional absorption‐based colorants inevitably leads to solar heating, which counteracts any radiative cooling effect. In this work, efficient sub‐ambient DRC (Day: −4 °C, Night: −11 °C) from a vibrant, structurally colored film prepared from naturally derived cellulose nanocrystals (CNCs), is instead demonstrated. Arising from the underlying photonic nanostructure, the film selectively reflects visible light resulting in intense, fade‐resistant coloration, while maintaining a low solar absorption (≈3%). Additionally, a high emission within the mid‐infrared atmospheric window (>90%) allows for significant radiative heat loss. By coating such CNC films onto a highly scattering, porous ethylcellulose (EC) base layer, any sunlight that penetrates the CNC layer is backscattered by the EC layer below, achieving broadband solar reflection and vibrant structural color simultaneously. Finally, scalable manufacturing using a commercially relevant roll‐to‐roll process validates the potential to produce such colored radiative cooling materials at a large scale from a low‐cost and sustainable feedstock.
Structurally colored films capable of full‐time sub‐ambient radiative cooling are prepared from a composite of cellulose nanocrystals and ethylcellulose. The distinct nanostructure within each layer allows for selective reflection of visible light generating color, whilst maintaining a broadband solar reflection. Finally, by demonstrating roll‐to‐roll fabrication, the potential for commercial production from this low‐cost and sustainable feedstock is substantiated.
Journal Article
Gravure‐Printed Flexible Perovskite Solar Cells: Toward Roll‐to‐Roll Manufacturing
by
Seo, Jangwon
,
Yang, Tae‐Youl
,
Kemppainen, Antti
in
flexible perovskite solar cells
,
gravure printing
,
Laboratories
2019
Recent advances in perovskite solar cells (PSCs) have resulted in greater than 23% efficiency with superior advantages such as flexibility and solution‐processability, allowing PSCs to be fabricated by a high‐throughput and low‐cost roll‐to‐roll (R2R) process. The development of scalable deposition processes is crucial to realize R2R production of flexible PSCs. Gravure printing is a promising candidate with the benefit of direct printing of the desired layer with arbitrary shape and size by using the R2R process. Here, flexible PSCs are fabricated by gravure printing. Printing inks and processing parameters are optimized to obtain smooth and uniform films. SnO2 nanoparticles are uniformly printed by reducing surface tension. Perovskite layers are successfully formed by optimizing the printing parameters and subsequent antisolvent bathing. 2,2′,7,7′‐Tetrakis‐(N,N‐di‐4‐methoxyphenylamino)‐9,9′‐spirobifluorene is also successfully printed. The all‐gravure‐printed device exhibits 17.2% champion efficiency, with 15.5% maximum power point tracking efficiency for 1000 s. Gravure‐printed flexible PSCs based on a two‐step deposition of perovskite layer are also demonstrated. Furthermore, a R2R process based on the gravure printing is demonstrated. The champion efficiency of 9.7% is achieved for partly R2R‐processed PSCs based on a two‐step fabrication of the perovskite layer.
Gravure printing for flexible perovskite solar cells is presented. A perovskite layer is successfully printed based on both one‐ and two‐step processes. The all‐printed flexible perovskite solar cells fabricated by sequential gravure printing of hole‐transporting, perovskite, and electron‐transporting layers exhibit 17.2% champion efficiency. Remarkably, partly roll‐to‐roll processed, flexible perovskite solar cells show 9.7% champion efficiency.
Journal Article
Tailoring the performance of nanocellulose-based multilayer-barrier paperboard using biodegradable-thermoplastics, pigments, and plasticizers
2023
In this work a multilayer barrier paperboard was produced in a roll-to-roll process by slot-die coating of nanocellulose (microfibrillated cellulose or carboxymethylated cellulose nanofibrils) followed by extrusion coating of biodegradable thermoplastics (polylactic acid, polybutylene adipate terephthalate and polybutylene succinate). Hyperplaty kaolin pigments were blended in different ratios into nanocellulose to tailor the barrier properties of the multilayer structure and to study their influence on adhesion to the thermoplastic top layer. Influence of a plasticizer (glycerol) on flexibility and barrier performance of the multilayer structure was also examined. Water vapor permeance for the multilayer paperboard was below that of control single-layer thermoplastic materials, and oxygen permeance of the coated structure was similar or lower than that of pure nanocellulose films. Glycerol as a plasticizer further lowered the oxygen permeance and kaolin addition improved the adhesion at the nanocellulose/thermoplastic interface. The results provide insight into the role played by nanocelluloses, thermoplastics, pigments, and plasticizers on the barrier properties when these elements are processed together into multilayer structures, and paves the way for industrial production of sustainable packaging.
Journal Article
Fabrication Methods for Microfluidic Devices: An Overview
2021
Microfluidic devices offer the potential to automate a wide variety of chemical and biological operations that are applicable for diagnostic and therapeutic operations with higher efficiency as well as higher repeatability and reproducibility. Polymer based microfluidic devices offer particular advantages including those of cost and biocompatibility. Here, we describe direct and replication approaches for manufacturing of polymer microfluidic devices. Replications approaches require fabrication of mould or master and we describe different methods of mould manufacture, including mechanical (micro-cutting; ultrasonic machining), energy-assisted methods (electrodischarge machining, micro-electrochemical machining, laser ablation, electron beam machining, focused ion beam (FIB) machining), traditional micro-electromechanical systems (MEMS) processes, as well as mould fabrication approaches for curved surfaces. The approaches for microfluidic device fabrications are described in terms of low volume production (casting, lamination, laser ablation, 3D printing) and high-volume production (hot embossing, injection moulding, and film or sheet operations).
Journal Article
Bicontinuous phase separation of lithium-ion battery electrodes for ultrahigh areal loading
by
Lee, Jung Tae
,
DeVolder, Michael
,
Jo, Changshin
in
Cathodes
,
Coated electrodes
,
Continuous coating
2020
Ultrathick battery electrodes are appealing as they reduce the fraction of inactive battery parts such as current collectors and separators. However, thick electrodes are difficult to dry and tend to crack or flake during production. Moreover, the electrochemical performance of thick electrodes is constrained by ion and electron transport as well as fast capacity degradation. Here, we report a thermally induced phase separation (TIPS) process for fabricating thick Li-ion battery electrodes, which incorporates the electrolyte directly in the electrode and alleviates the need to dry the electrode. The proposed TIPS process creates a bicontinuous electrolyte and electrode network with excellent ion and electron transport, respectively, and consequently achieves better rate performance. Using this process, electrodes with areal capacities of more than 30 mAh/cm2 are demonstrated. Capacity retentions of 87% are attained over 500 cycles in full cells with 1-mm-thick anodes and cathodes. Finally, we verified the scalability of the TIPS process by coating thick electrodes continuously on a pilot-scale roll-to-roll coating tool.
Journal Article
Multifunctional Micro/Nanostructured Interfaces, Fabrication Technologies, Wetting Control, and Future Prospects
by
Jang, Na Ye
,
Yoon, Seong Min
,
Cho, Young Tae
in
biomimetic replication
,
Interfacial energy
,
liquid repellency
2025
Recent advances in micro/nanostructured surfaces have facilitated the development of multifunctional materials with remarkable liquid repellency, anti‐fouling, particle capture, and electronic performances. Inspired by natural surfaces such as lotus leaves and springtail arthropod skin, these engineered interfaces employ hierarchical and reentrant geometries to regulate wetting behavior and interfacial energy. This review summarizes recent progress in the scalable fabrication of complex surface architectures, focusing on techniques such as UV nanoimprint lithography, digital light processing, and roll‐to‐roll imprinting. These approaches, often combined with advanced process innovations such as oxygen‐inhibited curing and mold tiling, have demonstrated the capability to fabricate precise large‐area microstructures with high throughput. Applications in superomniphobic, anti‐icing, anti‐microbial, and biomimetic replicas are highlighted, demonstrating both laboratory breakthroughs and industrial potential. Finally, the review addresses key challenges such as scalability, durability, and sustainability, and proposes future directions that integrate computational modeling. This review serves as a practical guide for researchers and engineers in the design and implementation of next‐generation functional surfaces.
This review explores recent developments in micro/nanostructured surfaces, with a focus on cavity‐based and reentrant geometries for enhanced liquid repellency and interfacial control. The review discusses fabrication strategies, structural design principles, and application trends, providing a balanced perspective on opportunities and ongoing challenges in functional surface engineering.
Journal Article
Multifunctional Micro/Nanostructured Interfaces, Fabrication Technologies, Wetting Control, and Future Prospects (Adv. Mater. Interfaces 22/2025)
by
Jang, Na Ye
,
Yoon, Seong Min
,
Cho, Young Tae
in
biomimetic replication
,
liquid repellency
,
microstructured surfaces
2025
Micro‐ and Nanostructured Surfaces
This cover highlights the multifunctional behaviors of nano‐ and microstructured surfaces. By focusing on microcavity‐based reentrant and hierarchical architectures, the design emphasizes liquid repellency as the fundamental property that enables anti‐icing and antimicrobial functions. The visual metaphor illustrates how structural engineering at multiple scales creates surfaces that not only repel liquids but also provide robust protection against environmental and biological challenges. More details can be found in the Review Article by Young Tae Cho and co‐workers (DOI: 10.1002/admi.202500492).
Journal Article
A review of roll-to-roll nanoimprint lithography
Since its introduction in 1995, nanoimprint lithography has been demonstrated in many researches as a simple, low-cost, and high-throughput process for replicating micro- and nanoscale patterns. Due to its advantages, the nanoimprint lithography method has been rapidly developed over the years as a promising alternative to conventional nanolithography processes to fulfill the demands generated from the recent developments in the semiconductor and flexible electronics industries, which results in variations of the process. Roll-to-roll (R2R) nanoimprint lithography (NIL) is the most demanded technique due to its high-throughput fulfilling industrial-scale application. In the present work, a general literature review on the various types of nanoimprint lithography processes especially R2R NIL and the methods commonly adapted to fabricate imprint molds are presented to provide a clear view and understanding on the nanoimprint lithography technique as well as its recent developments.PACS81.16.Nd
Journal Article
Highly efficient flexible structured metasurface by roll-to-roll printing for diurnal radiative cooling
2023
An ideal radiative cooler requires accurate spectral control capability to achieve efficient thermal emission in the atmospheric transparency window (8–13 μm), low solar absorption, good stability, scalability, and a simple structure for effective diurnal radiative cooling. Flexible cooling films made from polymer relying on polymer intrinsic absorbance represent a cost-effective solution but lack accuracy in spectral control. Here, we propose and demonstrate a metasurface concept enabled by periodically arranged three-dimensional (3D) trench-like structures in a thin layer of polymer for high-performance radiative cooling. The structured polymer metasurface radiative cooler is manufactured by a roll-to-roll printing method. It exhibits superior spectral breadth and selectivity, which offers outstanding omnidirectional absorption/emission (96.1%) in the atmospheric transparency window, low solar absorption (4.8%), and high stability. Impressive cooling power of 129.8 W m
−2
and temperature deduction of 7 °C on a clear sky midday have been achieved, promising broad practical applications in energy saving and passive heat dispersion fields.
Journal Article
Continuous roll-to-roll coating of cellulose nanocrystals onto paperboard
by
Abitbol, Tiffany
,
Jaiswal, Aayush Kumar
,
Koppolu, Rajesh
in
Adhesion
,
Adhesive strength
,
Alcohols
2018
There is an increased interest in the use of cellulose nanocrystal (CNC) films and coatings for a range of functional applications in the fields of material science, biomedical engineering, and pharmaceutical sciences. Most of these applications have been demonstrated on films and coatings produced using laboratory-scale batch processes, such as solvent casting, dip coating, or spin coating. For successful coating application of CNC suspensions using a high throughput process, several challenges need to be addressed: relatively high viscosity at low solids content, coating brittleness, and potentially poor adhesion to the substrate. This work aims to address these problems. The impact of plasticizer on suspension rheology, coating adhesion, and barrier properties was quantified, and the effect of different pre-coatings on the wettability and adhesion of CNC coatings to paperboard substrates was explored. CNC suspensions were coated onto pre-coated paperboard in a roll-to-roll process using a custom-built slot die. The addition of sorbitol reduced the brittleness of the CNC coatings, and a thin cationic starch pre-coating improved their adhesion to the paperboard. The final coat weight, dry coating thickness, and coating line speed were varied between 1–11 g/m
2
, 900 nm–7 µm, and 2.5–10 m/min, respectively. The barrier properties, adhesive strength, coating coverage, and smoothness of the CNC coatings were characterized. SEM images show full coating coverage at coat weights as low as 1.5 g/m
2
. With sorbitol as plasticizer and at coat weights above 3.5 g/m
2
, heptane vapor and water vapor transmission rates were reduced by as much as 99% and 75% respectively. Compared to other film casting techniques, the process employed in this work deposits a relatively thick coating in significantly less time, and may therefore pave the way toward various functional applications based on CNCs.
Graphical abstract
Journal Article