Large Area Roller Embossing of Multilayered Ceramic Green Composites

TL;DR

This paper demonstrates large area roller embossing of multilayered ceramic green composites, achieving high-quality patterning over 150mmx150mm panels with optimized parameters for industrial integration.

Contribution

Developed a modified roller embossing method compatible with screen printing for large area ceramic patterning, with optimized process parameters and demonstrated scalability.

Findings

Successful large area embossing on 150mmx150mm panels

Optimized parameters improve pattern quality

Pattern dimensions are consistent across the panel

Abstract

In this paper, we will report our achievements in developing large area patterning of multilayered ceramic green composites using roller embossing. The aim of our research is to pattern large area ceramic green composites using a modified roller laminating apparatus, which is compatible with screen printing machines, for integration of embossing and screen printing. The instrumentation of our roller embossing apparatus, as shown in Figure1, consists of roller 1 and rollers 2. Roller 1 is heated up to the desired embossing temperature ; roller 2 is, however, kept at room temperature. The mould is a nickel template manufactured by plating nickel-based micro patterns (height : 50 $\mu$m) on a nickel film (thickness : 70 $\mu$m) ; the substrate for the roller embossing is a multilayered Heraeus Heralock HL 2000 ceramic green composite. Comparing with the conventional simultaneous embossing, the advantages of roller embossing include : (1) low embossing force ; (2) easiness of demoulding ; (3) localized area in contact with heater ; and etc. We have demonstrated the capability of large area roller embossing with a panel size of 150mmx 150mm on the mentioned substrate. We have explored and confirmed the impact of parameters (feed speed, temperature of roller and applied pressure) to the pattern quality of roller embossing. Furthermore, under the optimized process parameters, we characterized the variations of pattern dimension over the panel area, and calculated a scaling factor in order to make the panel compatible with other processes. Figure 2 shows the embossed patterns on a 150mmx 150mm green ceramic panel.