光化学法腐蚀钢模工艺浅探

光化学腐蚀技术不仅广泛用于各种光学分划元件、印刷线路板、仪表标牌、面板等的制造,而且由于光化学腐蚀法加工具有精度高、成本低、周期短和设计方案修改方便等优点,已开始进入模具制造领域。本文将着重对用光化学腐蚀法制作移印钢模工艺中几个关键问题进行较详细的阐述。     

Thermal evolution of Co on the coexisting Ag/Ge(111)- \sqrt 3 \times \sqrt 3 and Ag/Ge(111)-4?×?4 phases

This study explores the suitability of microfibrillated cellulose (MFC) films as a substrate for printing electrically conductive structures and multilayer electronic structures such as organic field effect transistors. Various MFC qualities were tested, including mechanically produced MFC, 2,2,6,6-tetramethylpiperidinyl-1-oxyl pre-treated MFC and carboxymethylated-MFC. The films differed significantly with respect to the surface structure. In addition, the carboxymethylated-MFC films were surface modified with hexamethyldisilazane (HMDS) to reduce the water-wettability of the films, and thus, improve the print resolution of the inkjet-printed silver (Ag) nanoparticles. The Ag-particles (diameter?<?50?nm) were printed on the HMDS-modified films, which were mainly composed of nanofibrils with diameters <20?nm. The effect of surface roughness and surface chemical characteristics on the ink spreading and print resolution of the Ag-structures was explored. It was demonstrated that organic transistors operating at low voltages can be fabricated on nano-engineered MFC films.     

Multi-layered Ag film pattern printed by spatially modulated pulsed laser beam

Ag film solution-deposited on the glass source substrate was selectively transferred onto a receiver substrate by a spatially modulated pulsed ultraviolet laser beam. After printing a line pattern, an additional layer was orthogonally printed over the first layer. It was found that the thickness of the first layer is a crucial factor affecting the mechanical stability of the overall pattern. When the first layer was thicker than 0.7 μm, the second layer was cracked at the junction edges regardless of its thickness. This is attributed to the vertical elongation of the second layer at the edge areas. As long as the first layer remains below 0.7 μm thick, however, a very thick additional layer could be printed without any cracks. The printed patterns were mechanically robust and exhibited good electrical contact between the layers. The threshold pulse energy density for printing was measured to be 10 mJ/cm² and this threshold level made it possible to print over square centimeters by a single pulse.     

21.2%‐efficient fineline‐printed PERC solar cell with 5 busbar front grid

We evaluate industrial‐type PERC solar cells applying a 5 busbar front grid and fineline‐printed Ag fingers. We obtain finger widths down to 46 µm when using a stencil with 40 µm opening for the finger print, whereas the busbar is printed in a separate printing step with a different Ag paste (dual print). This compares to finger widths of 62 µm to 66 µm when applying print‐on‐print. The 5 busbar front grid with the best dual print process reduces the shadowing loss of the front grid to 4.0% compared to 5.8% for a conventional 3 busbar front grid printed with print‐on‐print. The 1.8% reduction in shadowing loss results in equal parts from the reduced finger width with dual print as well as from a reduced total busbar width of the 5 busbar design. The resulting PERC solar cells with 5 busbars demonstrate independently confirmed conversion efficiencies of 21.2% compared to 20.6% efficiency of the 3 busbar PERC solar cell. The increased conversion efficiency is primarily due to an increased short‐circuit current resulting from the reduced shadowing loss. To our knowledge, 21.2% conversion efficiency is the highest value reported so far for industry typical silicon solar cells with printed metal front and rear contacts. (© 2014 WILEY‐VCH Verlag GmbH &Co. KGaA, Weinheim)     

A novel approach for preparing silver nanoparticles under electron beam irradiation

Silver (Ag) nanoparticles were obtained when Ag microparticles were exposed to an electron beam in a transmission electron microscope (TEM). Results from TEM characterization indicated that the morphologies of the prepared Ag nanoparticles were quasi-circular, and the sizes were mainly in the range of 5–60 nm. The effect of irradiation time (t) on size and distribution of Ag nanoparticles was investigated. It was found that the sizes of Ag nanoparticles increased with the increase of t. The bigger Ag nanoparticles were near the Ag microparticle and the smaller ones were far from it. In addition, these Ag nanoparticles were monodisperse. This approach offered a new route for preparing Ag nanoparticles under electron beam irradiation, and the forming process of Ag nanoparticles was explained by the nucleation-growth mechanism.     

Proof‐of‐Concept Studies Directed toward the Formation of Metallic Ag Nanostructures from Ag3PO4 Induced by Electron Beam and Femtosecond Laser

In this work, for the first time, the instantaneous nucleation and growth processes of Ag nanoparticles on Ag₃PO₄ mediated by femtosecond laser pulses are reported and analyzed. The investigated samples are pure Ag₃PO₄ sample, electron‐irradiated Ag₃PO₄ sample, and laser‐irradiated sample. Complete characterization of the samples is performed using X‐ray diffraction (XRD), Rietveld refinements, field emission scanning electron microscopy, and energy dispersive spectroscopy (EDS). XRD confirms that the irradiated surface layer remains crystalline, and according to EDS analysis, the surface particles are composed primarily of Ag nanoparticles. This method not only offers a one‐step route to synthesize Ag nanoparticles using laser‐assisted irradiation with particle size control, but also reports a complex process involving the formation and subsequent growth of Ag nanoparticles through an unexpected additive‐free in situ fabrication process.     

Roll-to-roll gravure printed silver patterns to guarantee printability and functionality for mass production

This study introduces mass-producible roll-to-roll (R2R) gravure printed patterns with good printability and functionality. Ag flake materials and polyimide (PI) film substrates were used in this experiment. To confirm mass production potential, a large-scale R2R gravure machine was used, and lengthy printing times were used in the process (6.5 h). It was attempted to print a 30- to 120-μm fine-line pattern (groove type) and a 200- to 1000-μm-wide (dot type) nominal pattern. Various printed width and thickness values were obtained using many measurement sets to confirm the repeatability of each pattern for lengthy process times. We obtained a 45- to 1000-μm pattern width and a 1- to 5-μm thickness. Moreover, resistivity of the printed pattern was also achieved in the range of 5.4–18 μΩ cm. A peel-off test was performed using a standardized method. Finally, this paper presents the achieved optimized process condition and the results of this study.     

Size-dependent nonlinear absorption and refraction of Ag nanoparticles excited by femtosecond lasers

Silver (Ag) nanoparticles with different average sizes are prepared, and the nonlinear absorption and refraction of these nanoparticles are investigated with femtosecond laser pulses at 800 nm. The smallest Ag nanoparticles show insignificant nonlinear absorption, whereas the larger ones show saturable absorption. By considering the previously reported positive nonlinear absorption of 9 nm Ag nanoparticles, the nonlinear absorptions of Ag nanoparticles are found to be size-dependent. All these nonlinear absorptions can be compatibly explained from the viewpoints of electronic transitions, energy bands and electronic structures in the conduction band of Ag nanoparticles. The nonlinear refraction is attributed to the effect of hot electrons arising from the intraband transition in the s–p conduction band of Ag nanoparticles.     

Low temperature nanoparticle sintering with continuous wave and pulse lasers

New manufacturing methods are being sought for electronics production. Printable electronics is a promising method for producing low cost and large-scale electronics. In printable electronics nanoparticle inks printed on the surface of substrate contain additives, such as dispersing agent and carrier fluids that provide good printing properties by changing the viscosity and separating the nanoparticles of the ink. In the sintering process ink particles are heated to a certain, ink-specific temperature. During the sintering process the carrier fluid and dispersing agents are evaporated from the ink. Additional heating after evaporation causes the nanoparticles to start to agglomerate. A small particle size allows the use of a considerably lower sintering temperature than with bulk silver, for example 220 °C. The sintering process is usually utilized with a convection oven, with a long sintering time, and the thermal load on the surrounding material can become too great as components and patterns are formed from layers of different type inks. Hence, alternative sintering methods are sought. This paper describes tests done with two different types of laser; pulsed and continuous wave lasers. Laser sintering enables short sintering times and selective sintering, making it possible for printed structures to contain fragile active components produced with other technologies.     

Patterning and modification of PDMS surface through laser micromachining of silicon masters and molding

We describe preparation of micro patterned PDMS sample surfaces and their chemical modification for the purposes of increased hydrophobicity. The process includes ablation of micrometer sized patterns on a silicon master by pulsed radiation from a Nd:YAG laser, transfer of the patterns to PDMS through molding, and chemical modification of the topmost surface layers of the polymer sample by further laser irradiation and UV/ozone treatment. The samples were characterized by XPS, FTIR, contact angle measurements, optical microscopy and SEM. The study shows the feasibility of the method to manufacture regular patterns with micron-sized cylindrical pillars and to control surface composition. In the absence of chemical modification of the surfaces due to preparation, we compare the effect of increased roughness on the contact angle with theoretically predicted values. Samples with patterned and chemically modified surfaces due to UV/ozone treatment show reduced hydrophobicity. PACS 52.38.Mf; 81.65.Cf; 81.05.Lg