Sustainable and Eco-Friendly DLC Fabrication for Replacing Chrome on a Gravure Cylinder Surface.

This paper evaluates the potential of diamond-like carbon (DLC) as a durable surface protection to replace the chromium (Cr) layer, which is traditionally applied to gravure print cylinders and other components through a galvanic electroplating process. The fabrication of DLC is more eco-friendly and could reduce the environmental hazard posed by hexavalent chromium in liquid form that is used in Cr application and better adhere to environmental regulations. This could encourage businesses to bring the DLC fabrication process in-house, sharing resources such as materials, labor, and equipment, to help reduce costs. Four DLC variants (standard DLC, A-DLC, S-DLC, and organic silica) and chrome were analyzed and tested for their surface properties and durability. Data suggest that both standard DLC and S-DLC had higher surface free energy, allowing for good ink wetting on the surface when compared to chrome. In addition, the standard DLC and S-DLC surfaces are generally smoother than the chrome, resulting in lower relative hydrophilicity and allowing for easier removal of ink in the nonimage regions with the doctor blade. The elcometer adhesion test demonstrated that the bond strength of the DLC variants to their base layer was comparable to the bond strength of chrome, indicating that the adhesion strength of the two materials was similar. Furthermore, in the abrasion test, the wear on the standard DLC surface and the corresponding wear on the lamella tip of the metal doctor blades were notably lower than that observed on chrome. This distinction is particularly evident in each of the test trials, specifically run 1, which involved 2,000,000 wiping actions of a metal doctor blade in the presence of abrasive TiO2 ink pigments. Statistical analysis on standard DLC versus chrome suggests that DLC fabrication is effective and durable on plain and patterned surfaces. Therefore, from a sustainable and eco-friendly perspective, standard DLC and S-DLC would be good alternative durable surfaces for print cylinders and other components used in various industries due to superior wear resistance properties.

Controlling unequal surface energy results caused by test liquids: the case of UV/O3 Treated PET.

Ultraviolet/ozone (UV/O3) treatment has been reported to be an effective method to modify properties such as wettability, adhesion or adsorption of plastic surfaces. The change in the surface is measured by contact angle analysis, which employs liquids and their surface tensions (ST) to estimate the surface energy (SE). We found two different practices in the scientific community: (1) the majority of researchers adopted the ST value of liquids from the literature, while (2) other researchers conducted real-time measurements in the lab under ambient conditions prior to SE estimation. To the best of our knowledge, there is no study that compares the difference between the two practices. One study was found to show different SE methods generating unequal SE values for the same substrate. However, there was no definitive conclusion backed by general thermodynamics rules. In this study, we presented (1) a statistical significance test that showed the literature and experimental ST values are significantly different, and studied (2) the effect of different liquid pairs on the SE estimation for UV/O3 treated poly(ethylene terephthalate) (PET) substrate. Modification techniques such as atmospheric pressure plasma or chemical modification were studied previously to examine PET's wettability and the SE. The UV/O3 treatment was studied to improve adhesion and to modify its chemical properties for adsorption. In contrast, we studied (3) the effect of UV/O3 on wettability at different timeframes and addressed (4) how to control unequal SE based on a method that was refined on a rigorous thermodynamic three-phase system. It must be noted that this method can be generalized to other types of solid surfaces to estimate thermodynamically self-consistent SE values. This work also provides (5) a web-based calculator that complements computational findings available to the readership in the data availability section.

One-step photonic curing of screen-printed conductive Ni flake electrodes for use in flexible electronics.

Photonic curing has shown great promise in maintaining the integrity of flexible thin polymer substrates without structural degradation due to shrinkage, charring or decomposition during the sintering of printed functional ink films in milliseconds at high temperatures. In this paper, single-step photonic curing of screen-printed nickel (Ni) electrodes is reported for sensor, interconnector and printed electronics applications. Solid bleached sulphate paperboard (SBS) and polyethylene terephthalate polymer (PET) substrates are employed to investigate the electrical performance, ink transfer and ink spreading that directly affect the fabrication of homogeneous ink films. Ni flake ink is selected, particularly since its effects on sintering and rheology have not yet been examined. The viscosity of Ni flake ink yields shear-thinning behavior that is distinct from that of screen printing. The porous SBS substrate is allowed approximately 20% less ink usage. With one-step photonic curing, the electrodes on SBS and PET exhibited electrical performances of a minimum of 4 Ω/sq and 16 Ω/sq, respectively, at a pulse length of 1.6 ms, which is comparable to conventional thermal heating at 130 °C for 5 min. The results emphasize the suitability of Ni flake ink to fabricate electronic devices on flexible substrates by photonic curing.