A continuous roll-to-roll manufacturing process is a next-generation process for the environmentally friendly and low-cost mass production of functional printed devices. Unlike paper product printing, a thin plastic web used as a base film in printed electronic devices is exceptionally vulnerable to elastic and thermal deformations owing to its viscoelastic characteristic, which makes the fabrication of highly integrated printed functional devices very challenging. Herein, we review the representative studies regarding the tension applied to the web during the roll-to-roll process and alternatives for compensating web deformation errors. Also, we introduce the development of the theoretical models expressing the dynamics of tension and lateral motion during the web transporting process. We also discuss applicable controllers for compensating the tension and lateral errors and discuss register errors and associated control techniques. Finally, we summarize the mathematical model applied to the internal stress in wound roll and winding tension control techniques, highlighting the idea that defects in the wound roll can be decreased by controlling the winding tension. The review can be helpful in the design of web dynamic control systems in the multi-layer roll-to-roll manufacturing process.

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卷对卷制造过程中Web处理的理论和控制技术

连续卷对卷制造工艺是功能性印刷设备的环保，低成本批量生产的下一代工艺。与纸制品印刷不同，由于其粘弹性特性，在印刷电子设备中用作基膜的薄塑料幅材极易受到弹性和热变形的影响，这使高度集成的印刷功能设备的制造非常具有挑战性。本文中，我们回顾了有关卷对卷过程中施加到卷筒纸上张力的代表性研究，以及用于补偿卷筒纸变形误差的替代方法。另外，我们介绍了理论模型的发展，这些模型表达了在纸幅运输过程中张力和横向运动的动力学。我们还将讨论用于补偿张力和横向误差的适用控制器，并讨论套准误差和相关的控制技术。最后，我们总结了适用于绕线辊内应力和绕线张力控制技术的数学模型，强调了通过控制绕线张力可以减少绕线辊缺陷的想法。该评论对多层卷对卷制造过程中的Web动态控制系统的设计很有帮助。