超精密共軸線上轉印系統開發應用於超細長曲線型微奈米銀導線電路陣列成形研究

In this study, a novel co-shaft in-situ rolling-imprinting technique is proposed for fabricating silver micro-nanowire arrays with ultra-high slenderness ratios on transparent polyethylene terephthalate (PET) films. The rolling-imprinting system integrates two key mechanisms: micro rolling-tooth array mold cutting and silver micro-nanowire array imprinting. These processes are executed within the same coordinate system and share the same rolling shaft center, ensuring exceptional concentric accuracy and minimizing swaying errors. As a result, the system enables the formation of ultra-thin, highly aligned, and either parallel or regularly curved silver wire arrays. To ensure a stable, micro-quantity, and precisely controlled supply of silver paste, a specialized delivery mechanism is designed. This mechanism utilizes fine screw threads to guide the paste into a comb-shaped microchannel array. By adjusting the surface roughness so that the contact angle of the silver paste on the roller mold exceeds that on the PET film, the transfer and release of the paste onto the PET substrate is significantly enhanced. A doctor-blade placement system featuring dual variables, optimal letterpress width and minimal letterpress gap, is introduced to effectively remove excess silver paste and minimize wire width during imprinting. Experimental results demonstrate that silver paste molecules exhibit optimal congregation behavior, yielding minimal wire widths when using a 5-μm letterpress width, 1-μm letterpress gap, and a roller mold surface roughness of Ra 6 nm. These findings validate the intrinsic internal force balance characteristic of the silver paste. The resulting silver micro-nanowire arrays, with dimensions of 5 μm in width and 1 μm in thickness, exhibit ultra-high slenderness ratios, excellent straightness, uniformity, and regularity, and are capable of reliably powering LED devices. Furthermore, the study introduces a steady-state simple harmonic servo motion cutting technique combined with in-situ oblique fine cutting to fabricate wave-shaped micro rolling-tooth array molds. These molds enable the roll-printing of serpentine silver micro-nanowires with lengths up to 100 mm and widths of 35 μm. The conductive films incorporating both straight and serpentine silver micro-nanowires demonstrate superior electrical conductivity (σ = 1.94×10? S/m and 1.77×10? S/m) and high optical transmittance (T = 90.5% and 89.9%), outperforming commercial indium tin oxide (ITO) films (σ = 9.26×10? S/m, T = 78.3%). These results confirm the feasibility of replacing ITO films with the proposed transparent conductive silver wire arrays for advanced circuit routing applications.