N-colour separation methods for accurate reproduction of spot colours

In packaging, spot colours are used to print key information like brand logos and elements for which the colour accuracy is critical. The present study investigates methods to aid the accurate reproduction of these spot colours with the n-colour printing process. Typical n-colour printing systems consist of supplementary inks in addition to the usual CMYK inks. Adding these inks to the traditional CMYK set increases the attainable colour gamut, but the added complexity creates several challenges in generating suitable colour separations for rendering colour images. In this project, the n-colour separation is achieved by the use of additional sectors for intermediate inks. Each sector contains four inks with the achromatic ink (black) common to all sectors. This allows the extension of the principles of the CMYK printing process to these additional sectors. The methods developed in this study can be generalised to any number of inks. The project explores various aspects of the n-colour printing process including the forward characterisation methods, gamut prediction of the n-colour process and the inverse characterisation to calculate the n-colour separation for target spot colours. The scope of the study covers different printing technologies including lithographic offset, flexographic, thermal sublimation and inkjet printing. A new method is proposed to characterise the printing devices. This method, the spot colour overprint (SCOP) model, was evaluated for the n-colour printing process with different printing technologies. In addition, a set of real-world spot colours were converted to n-colour separations and printed with the 7-colour printing process to evaluate against the original spot colours. The results show that the proposed methods can be effectively used to replace the spot coloured inks with the n-colour printing process. This can save significant material, time and costs in the packaging industry

Inkjet etching of micro-via holes in thin polymer layers

Facilitated by the development of various direct-write techniques and functional polymeric materials including polymer based conductors and semiconductors, printed electronics are flourishing both commercially and as a research topic. This is not only because of their simpler manufacturing routes and lower cost, but also as a result of lower processing temperatures and better compatibility with flexible substrates, compared with conventional electronics. The development of conventional electronics has been guided by Moore s Law, the driver for which lies in the demand for electronic devices with better performance and portability at lower prices. Therefore, one can expect a similar trend for printed electronics to guide its development. Multi-layered printing can be adopted in printed electronics to achieve higher density integration, so that this development trend can be maintained. In such circumstances, creation of electrical connections between multiple layers emerges as an important issue for printed electronics. Inkjet-etched via holes are one potential solution to providing such electrical interconnections, and which can provide good integration with other inkjet-printed features simply by switching nozzles. This thesis aims to elicit a better understanding of the physics involved in inkjet etching and investigate the capability of the inkjet etching technique. In the thesis, the factors that can affect the size of via holes produced by inkjet etching are evaluated, which is significant for evaluating the capability of this technique to deliver industrially relevant features. Identified factors include droplet ejection frequency, droplet diameter, solvent properties and substrate temperature. Droplet ejection frequency, i.e. the reciprocal of the time interval between drops, determines the extent of evaporation of the solvent between two consecutive drop impacts. Droplet diameter determines the radius of the wetted area after the droplet I impacts on the surface and spreads into a sessile drop. Solvents with different evaporation properties result in different size evolution with the number of drops dispensed, as does droplet ejection frequency. Higher substrate temperatures can reduce the drop diameter during flight and decrease the evaporation time on polymer surfaces, which can shrink the size of via holes. Another important issue is achieving complete polymer penetration as residual polymer creates an electrical conduction barrier after such holes are subsequently filled with conductive materials or act as a barrier to filling by electroplating. Experiments have been carried out to test the effect of outer diameter and polymer thickness on polymer penetration. Electroplating is utilised to test the completeness of via hole penetration. A mechanism using the Marangoni effect to explain the protrusion drying pattern other than a hole in the polymer layer is proposed

Design and development of a microfluidic platform for use with colorimetric gold nanoprobe assays

Due to the importance and wide applications of the DNA analysis, there is a need to make genetic analysis more available and more affordable. As such, the aim of this PhD thesis is to optimize a colorimetric DNA biosensor based on gold nanoprobes developed in CEMOP by reducing its price and the needed volume of solution without compromising the device sensitivity and reliability, towards the point of care use. Firstly, the price of the biosensor was decreased by replacing the silicon photodetector by a low cost, solution processed TiO2 photodetector. To further reduce the photodetector price, a novel fabrication method was developed: a cost-effective inkjet printing technology that enabled to increase TiO2 surface area. Secondly, the DNA biosensor was optimized by means of microfluidics that offer advantages of miniaturization, much lower sample/reagents consumption, enhanced system performance and functionality by integrating different components. In the developed microfluidic platform, the optical path length was extended by detecting along the channel and the light was transmitted by optical fibres enabling to guide the light very close to the analysed solution. Microfluidic chip of high aspect ratio (~13), smooth and nearly vertical sidewalls was fabricated in PDMS using a SU-8 mould for patterning. The platform coupled to the gold nanoprobe assay enabled detection of Mycobacterium tuberculosis using 3 8l on DNA solution, i.e. 20 times less than in the previous state-of-the-art. Subsequently, the bio-microfluidic platform was optimized in terms of cost, electrical signal processing and sensitivity to colour variation, yielding 160% improvement of colorimetric AuNPs analysis. Planar microlenses were incorporated to converge light into the sample and then to the output fibre core increasing 6 times the signal-to-losses ratio. The optimized platform enabled detection of single nucleotide polymorphism related with obesity risk (FTO) using target DNA concentration below the limit of detection of the conventionally used microplate reader (i.e. 15 ng/μl) with 10 times lower solution volume (3 μl). The combination of the unique optical properties of gold nanoprobes with microfluidic platform resulted in sensitive and accurate sensor for single nucleotide polymorphism detection operating using small volumes of solutions and without the need for substrate functionalization or sophisticated instrumentation. Simultaneously, to enable on chip reagents mixing, a PDMS micromixer was developed and optimized for the highest efficiency, low pressure drop and short mixing length. The optimized device shows 80% of mixing efficiency at Re = 0.1 in 2.5 mm long mixer with the pressure drop of 6 Pa, satisfying requirements for the application in the microfluidic platform for DNA analysis.Portuguese Science Foundation - (SFRH/BD/44258/2008), “SMART-EC” projec

The development of multi-channel inkjet printing methodologies for fine art applications

This thesis contributes to the defence of the practitioner perspective as a means of undertaking problems addressed predominantly in the field of colour science. Whilst artists have been exploring the use of colour for centuries through their personal practice and education, the rise of industrialised printing processes has generated a shift in focus away from these creative pursuits and into the computational field of colour research. It is argued here that the disposition and knowledge generated by creative practice has significant value to offer developing technologies. While creative practice has limited influence in the development of colour printing, practitioners and users of technology actively engage with the process in ways that extend beyond its intended uses in order to overcome recognised shortcomings. Here consideration is given to this creative engagement as motivation to develop bespoke printing parameters that demonstrate the effects of colour mixing through methods alternative to standard workflows. The research is undertaken incorporating both qualitative and quantitative analysis, collecting data from visual assessments and by examining spectral measurements taken from printed output. Action research is employed to directly access and act upon the constant developments in the art and science disciplines related to inkjet printing, observing and engaging with current methods and techniques employed by practitioners and developers. This method of research has strongly informed the empirical testing that has formed this thesis’s contribution to fine art inkjet printing practice. The research follows a practitioner led approach to designing and testing alternative printing methods and is aimed at expanding the number of discernible colours an inkjet printer can reproduce. The application of this methodology is evidenced through demonstrative prints and a reproduction study undertaken at the National Gallery, London. The experimentation undertaken in partnership with the National Gallery has proven the ability to increase accuracy between colour measured from the original target and reproduction, beyond the capabilities of current inkjet printing workflows

Printing Conductive Paths for Electronic Functional Devices

Printing inorganic and organic materials has been attracting plenty of researchers and scientists as an alternative to the conventional photolithography and electroless deposition methods due to the complications, time-consuming, size restrictions and high costs that these methods usually experience. Soft lithographic techniques and inkjet printing technology have offered simpler, lower costs and faster alternatives. One of the main objectives of this study is the contribution to these alternatives by utilising a cost-effective, simple and easy-to-use stamp printing machine in the deposition of metal patterns from poly(dimethylsiloxane) (PDMS) stamps onto treated glass substrates. Two drop-on-demand inkjet printers; one is a commercial desktop piezoelectric printer and a second thermal PEL printing and coating platform, were utilised to inkjet print functional materials. The cheap piezoelectric one used to deposit silver nanoparticles and poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS) inks. By utilising this technology, innovative flexible information storage devices, electronic memory cells, were inkjet printed. All the components (silver electrodes and PEDOT:PSS active layer) of these memory devices were fully deposited by this simple desktop inkjet printer on a flexible substrate (ceramic coated PEL paper) at room temperature. The thermal printing machine, on the other hand, was employed to print graphene oxide on the PEL paper. These techniques also provide hope to develop environmentally friendly processes of fabrication used in the electronics and semiconductor industry and minimise the wastage of materials and power

Preparation and optimisation of transparent conducting patterns using inkjet printing

Transparent conducting patterns (TCPs) are critical components that are required to be integrated into photovoltaic (PV) cells for energy harvesting. Among the manufacturing processes that are available for the deposition of TCPs onto various substrates, inkjet printing which can be categorised as an additive dispensing process has demonstrated its competitiveness by offering numerous advantages, including non-contact, high resolution, high printing speed, low cost and low material consumption. However, the present bottlenecks to be overcome for further take-up of inkjet printing technology imperatively demand the understanding of materials behaviour involved in the ink formulation and printing process. This thesis is dedicated to the elaboration of fundamental aspects of technical challenges that have been encountered in the uses of inkjet printing technology for the generation of TCPs, thereby optimisation of functional properties of the printed patterns can be achievable through the modification of inks and optimum parameters used in the printing process. [Continues.

Fluid characterisation and drop impact in inkjet printing for organic semiconductor devices

An inkjet printer can deposit a very small volume of liquid with high positional accuracy, high speed and low cost. As a maskless, non-contact additive patterning method, inkjet printing technology is increasingly being explored as an alternative to lithography, etching and vapour deposition processes to pattern electrical conductors and thin films with applications in printed electronic devices. The functional inks used in many of the applications involve non-linear viscoelasticity and their behaviours in the context of inkjet printing have not been fully understood. This thesis aims to characterise Newtonian and non-Newtonian properties of inkjet fluids and identify the key parameters affecting drop impact and spreading processes. Various fluid characterisation techniques such as the filament stretching rheometer and piezoelectric axial vibrator are explored. We propose an experimental method to assess the jettability of non-Newtonian inkjet fluids, without using an inkjet print head. The oblique collision of two continuous liquid jets leads to the formation of a thin oval liquid sheet bounded by a thicker rim which disintegrates into ligaments and droplets. Under certain conditions the flow structure exhibits a remarkably symmetrical “fishbone” pattern composed of a regular succession of longitudinal ligaments and droplets. Good correlation was found between the maximum included angle of the fishbone pattern and the maximum ligament length in the jetting experiments, which suggests that a test based on oblique impinging jets may be useful in the development of fluids for ink jet printing. High-speed imaging is used to analyse the impact and spreading of sub-30 μm drops of diethyl phthalate or polystyrene solutions in diethyl phthalate on to smooth glass surfaces with controlled wettability at speeds from 3 to 8 m s-1, under conditions representative of drop-on-demand inkjet printing. Data on drop height and spreading diameter are generated with high time and spatial resolution, over eight orders of magnitude in timescale. The effects of fluid viscosity and elasticity, which significantly affect jetting performance, are negligible throughout the whole deposition process, with no significant difference between spreading curves. The values of the fluid surface tension and the substrate wettability also have no effect on the kinematic, spreading or relaxation phases, but a marked influence on the wetting phase, in terms of the speed of expansion of the contact diameter and the final spreading factor

Conducting metal oxide materials for printed electronics

Printed electronics as a manufacturing process has many advantages, mainly, it allows for the high throughput rapid fabrication of thin, flexible electronic components with minimal waste. There are many printing processes that can be utilised for printing electronics and although each process can differ vastly, the materials currently used in these processes are generally the same, silver and carbon. However, to develop printing as a more mainstream manufacturing method for electronics, a wider variety of materials are required which can provide better stability and longevity of components, new functionality for printed applications and allow for in-situ processing and tuning of components. Conducting metal oxides are a good candidate for integrating into printed electronics processes, these materials are typically semiconductors, they have bandgaps, and properties can be altered via altering the band gap. They are also oxides, so they cannot oxidise further and therefore atmospheric damage is reduced compared to pure metals. They can also be fabricated into a wide range of particle morphologies, all with advantages in different fields and electronic applications. Therefore, the ability to print these materials is valuable to the field. In this thesis, the integration of conducting metal oxide electro-ceramic materials into the field of printed electronics has been explored. This was performed through the completion of five research objectives including, the selection of appropriate materials for the research, the formulation of conductive inks with the materials, the investigation of post-processing techniques for printed films and further research into passive component fabrication and sensor applications. Firstly, following an extensive literature review, four materials were selected including three doped zinc oxide materials synthesised via different methods. The fourth material is commercially sourced indium tin oxide (ITO). A nitrocellulose vehicle was determined to be the most compatible with the oxides and selected for ink formulation. Inks were then formulated with all four materials, with optical and electrical properties analysed. Gallium doped Zinc Oxide (GZO) and ITO were selected for further investigation based on the excellent conductivity of the indium tin oxide (57.77Ω□-1) and the highly transparent optical properties of the gallium doped zinc oxide (>84% transmittance). Laser processing was selected as a post processing method. It was found that the laser processing dramatically increased conductivity. The GZO improving from a non-conductive film to 10.21% of bulk conductivity. The ITO improved from 3.46% to 40.47% of the bulk conductivity. It was also found that the laser processing invoked a carbothermal reduction process allowing for a rapid manufacturing process for converting spherical particles into useful nanoparticle morphologies (nanorods, nanowires etc). Following this, resistive and capacitive applications involving laser processing and conventionally heat-treated conductive oxide inks were developed. Combining the new materials and manufacturing processes, tuneable printed resistors with a tuning range of 50 to 20M could be fabricated. All metal oxide, ITO based capacitors were also fabricated and characterised. These were then developed into humidity sensors which provided excellent humidity sensing properties, showing linearity between 5 and 95% relative humidity (RH) and sensitivities of up to 7.76pF/RH%, demonstrating higher performance than commercial equivalents (0.2 – 0.5pF/RH%). In conclusion, this work provides a breakthrough for conductive metal oxide materials research and its place in Printed Electronics research by providing insight into the processes required to make these materials conduct and by developing useful manufacturing methods, post processing techniques and applications.</div