Functional Modelling of Water Vapour Transmission through Surface Defects Using Surface Segmentation Analysis

Flexible photovoltaic films have been recently shown to have efficiencies comparable to those of solid Si based photovoltaics. Flexible PV films have significant advantages in terms of ease of manufacture by roll-to-roll (R2R) techniques and in easy building integration. A significant challenge is the protection of the flexible solar cells from water vapour ingress, which seriously reduces cell life and efficiency. Transparent barrier films are a possible solution to addressing the water vapour transmission rate (WVTR) challenge. Consequently thin barrier films such as those made from Al2O3 are the subject of increasing research interest when used for the encapsulation of flexible PV modules. The film can be produced by several thin film deposition processes such as atomic layer deposition (ALD). However, micro-scale defects in the barrier film such as pinholes and particulate debris have been shown to have serious consequences in terms of WVTR. Our previous research has empirically shown that small defects (≤3μm lateral dimension) were less significant in determining water vapour ingress. In contrast, larger defects (≥3 μm lateral dimension) have been shown to have a greater effect on the barrier functionality. The present paper illustrates the use of surface segmentation techniques to efficiently extract defect data from measured surface topography of barrier film sheets. Experimental results are presented where the defect information is correlated with the WVTR tests. A model is then presented to test the hypothesis that the major contributing defects to water vapour transmission rate (WVTR) are small numbers of large defects. The model presented in the paper shows excellent correlation with experimental results and provides a theoretical basis for the development of in process surface measurement for thin film R2R manufacture

Nano scale Characterisation of Photovoltaic Ultra Barrier Films

This paper reports on the recent work carried out as part of the EU funded NanoMend project. The project seeks to develop integrated process inspection, cleaning, repair and control systems for nano-scale thin films on large area substrates

Material removal investigation in bonnet polishing of CoCr alloy

The manufacture of orthopaedic joint bearings surfaces requires exceptionally high levels of control of not only the surface finish but also the surface form. In the case of hip joints, the form of femoral head should be controlled to within ± 50ìm from a given diameter. It has been shown that a better form control of bearing component could enhance clearances creating the correct volume of lubrication to fill the bearing surface gap and reduce wear particle generation. This element is especially critical for the new generation non-spherical head designs. Bonnet polishing which is used successfully in the area of optics is potentially an excellent finishing process to control the form and finish of artificial joints. In the process of form control polishing an “influence function” which defines the material removal rate is of vital importance in developing a corrective polishing procedure. However, the effects of polishing parameters (such as precess angle, head speed, tool pressure and tool offset) on influence function are not very clear for CoCr alloys. These elements must be assessed if a deterministic polishing process is to be developed. Therefore, it is of paramount importance to understand the contribution of each polishing factors to influence function and consequent part polishing. This study has investigated the effects of polishing parameters on influence function, including geometric size and volumetric material removal rate (MRR). The experimental results indicate that the polishing parameter of precess angle and tool offset affect the geometric size of influence function significantly; the polishing parameter of head speed and tool pressure affect the geometric size of influence function to a lesser degree; the polishing parameter of precess angle, head speed and tool offset affect MRR greatly

The topographic development and areal parametric characterization of a stratified surface polished by mass finishing

Mass finishing is amongst the most widely used finishing processes in modern manufacturing, in applications from deburring to edge radiusing and polishing. Processing objectives are varied, ranging from the cosmetic to the functionally critical. One such critical application is the hydraulically smooth polishing of aero engine component gas-washed surfaces. In this, and many other applications the drive to improve process control and finish tolerance is ever present. Considering its widespread use mass finishing has seen limited research activity, particularly with respect to surface characterization. The objectives of the current paper are to; characterise the mass finished stratified surface and its development process using areal surface parameters, provide guidance on the optimal parameters and sampling method to characterise this surface type for a given application, and detail the spatial variation in surface topography due to coupon edge shadowing. Blasted and peened square plate coupons in titanium alloy are wet (vibro) mass finished iteratively with increasing duration. Measurement fields are precisely relocated between iterations by fixturing and an image superimposition alignment technique. Surface topography development is detailed with ‘log of process duration’ plots of the ‘areal parameters for scale-limited stratified functional surfaces’, (the Sk family). Characteristic features of the Smr2 plot are seen to map out the processing of peak, core and dale regions in turn. These surface process regions also become apparent in the ‘log of process duration’ plot for Sq, where lower core and dale regions are well modelled by logarithmic functions. Surface finish (Ra or Sa) with mass finishing duration is currently predicted with an exponential model. This model is shown to be limited for the current surface type at a critical range of surface finishes. Statistical analysis provides a group of areal parameters including; Vvc, Sq, and Sdq, showing optimal discrimination for a specific range of surface finish outcomes. As a consequence of edge shadowing surface segregation is suggested for characterization purposes

Flexible shape extraction for micro/nano scale structured surfaces.

Surface feature is the one of the most important factors affecting the functionality and reliability of micro scale patterned surfaces. For micro scale patterned surface characterisation, it’s important to extract the surface feature effectively and accurately. The active contours, known as “snakes”, have been successfully used to segment, match and track the objects of interest. The active contours have been applied to facial boundary detection, medical image processing, motion correction, etc. In this paper, surface feature extraction techniques based on active contours have been investigated. Parametric active contour models and geometric active contour models have been presented. Also, a group of examples has been selected here to demonstrate the feasibility and applicability of the surface pattern extraction techniques based on active contours. At last, experimental results will be given and discussed

The application of Taguchi approach to optimise the processing conditions on bonnet polishing of CoCr

This paper applied the Taguchi approach to investigate the effects of each polishing parameter and obtain the optimal processing conditions for CoCr alloy polishing. The polishing medium was 1µm diamond paste with Microcloth(polishing cloth). Surface finish parameter Sa was chosen as criterion for optimization. The experimental result indicates that the optimal polishing condition for CoCr alloy polishing is 5deg of precess angle, 800 rpm of head speed, 0.2mm of tool offset and 1.5 bar of tool pressure. With this optimal condition, a confirmatory experiment was conducted. The surface roughness Sa reduced from initial 24nm to 7nm and reduction ratio was 72.5% which was very close to the estimated ratio 64%

Implementation of wavelength scanning interferometry for R2R flexible PV barrier films

Roll to Roll manufacture of nano-scale thinf ilm layers faces the challenge of micro/nano-scale defects appearing in the films. Atomic Layer Deposition (ALD) coatings of aluminium oxide, Al2O3 are used as barrier layers for photovoltaic (PV) solar modules where the primary function of the barrier layer is to prevent the water vapour ingress to the PV cells. Barrier layer defects have been shown to have negative impact on the performance of the barrier layers. Poor barriers cause module degradation resulting in reduced PV efficiency and lifespan. In order to ensure the quality of manufacture of the barriers, defects should be detected during the barrier production process and the information used to optimise the production process. This paper introduces, as part of EU funded NanoMend project, a full solution for inspection of entire surface regions of Al2O3 barrier films across large area substrates. The solution principle is based on implementing an opto-mechanical in-process inspection system to measure the significant defects using a wavelength scanning interferometer (WSI) embedded within the film-rewinder stage and integrated with the substrate translation and kinematic stages. The opto-mechanical system allows full surface measurement over full substrate widths of approximately 0.5m. The system provides an auto-focus for the WSI with an accuracy and repeatability better than 6 µm at optimum optical alignment conditions. The system is combined with a porous air-bearing conveyor used to hold the film web at fixed height within the focal depth of WSI objective lens and with height variation of 3 µm is also presented as a case study to highlight the system capability

Correlation of micro and nano–scale defects with WVTR for aluminium oxide barrier coatings for flexible photovoltaic modules

This paper seeks to establish a correlation between surface topographical defects and water vapour transmission rate (WVTR) measured under laboratory conditions for aluminium–oxide (Al2O3) barrier film employed in flexible photovoltaic (PV) modules. Defects in the barrier layers of PV modules causing high WVTR are not well characterised and understood. A WVTR of ~10−1 g/m2/day is sufficient for the most packaging applications, but ≤10−6 g/m2/day is required for the encapsulation of long–life flexible PV modules (Carcia et al., 2010a, 2010b). In this study, surface metrology techniques along with scanning electron microscopy (SEM) were used for a quantitative characterisation of the barrier film defects. The investigation have provided clear evidence for the correlation of surface defect density and the transmission of water vapour through the barrier coating layer. The outcomes would appear to suggest that small numbers of large defects are the dominant factor in determining WVTR for these barrier layers

Wavelength Scanning Interferometery for large area roll to roll metrology applications in photovoltaic manufacturing environment

The wavelength scanning interferometer is currently being applied as a core metrology technology as part of the EU project NanoMend - Nanoscale Defect Detection, Cleaning and Repair for Large Area Substrates ̴500 mm width. NanoMend Project aims to develop technologies that are able to detect and correct micro and nano-scale defects in roll-to-roll produced films in order to improve product performance, yield and lifetime

Metrology for Bio Systems

The current paper addresses the advent of next generation bio system focussed Micro Nano Manufacturing Technologies (MNMT). These products and processes have placed significant new emphasis on specification and quality control systems, especially if these product and processes are to achieve economic scale up. Bio technology products and processes are a core element of MNMT and structured surfaces can be a key element in enabling bio system function. There examples of the application of such surfaces in bio systems for functions such as diverse as anti fouling and oseointegration. However a deficit exists in terms of metrology for bio structured surfaces and identifying suitable measurands and instrumentation remains a challenge for production engineers. Functional modelling would seem to point towards a better way of specifying metrology however for bio systems these are rare and often extensive function testing and clinical trials are used to inform the metrology selection. In the present paper the development of MNMT bio systems is discussed in the metrology context and several examples of developing metrology challenges. Four such bio related systems are discussed the solutions are outlined. The case studies cover traditional prosthetic implants, micro fluidic devices, cellular attachment and manufacture of cellular scaffolds