多管微流道同步機制與高通量「太極塗佈」系統之開發研究

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doi:10.6342/NTU201603414

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多管微流道同步机制与高通量「太极涂布」系统之开发研究

Development of synchronization for multi-microchannel and high-throughput “Air-Bubble Coating” system

谢育文 , 博士　　导师：王安邦　　

繁体中文 DOI： 10.6342/NTU201603414

太极涂布法；液气微双相流；即时尺寸控制；即时检测；同步机制； Air-Bubble Coating ； gas-liquid micro-two-phase flow ； real-time size control ； on-line detection ； synchronization mechanism

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摘要 │ 参考文献 (241) │ 国际计量

摘要〈TOP〉

随着消费性电子产品的需求逐年提升，各式各样的涂布技术已被大量应用於高科技产业，其中不需母模的图案化涂布技术因其环保节能的特性，已渐渐成为发展主流。太极涂布法即是一新兴的不需母模图案化涂布技术，透过将间断式的液气微双相流连续地涂布於基材上而产生非连续的涂布图案，具有作动简单、涂料黏度适用范围广及可兼容卷对卷(roll-to-roll)方式生产等优越特性。本研究为将此新兴技术推广至工业化量产的前导型研究，根据所需开发的关键技术将论文架构分为三大部分：
I. 液气微双相流即时尺寸控制系统之开发：
此部分首先探讨流体输入源对液气微双相流尺寸均匀性的影响，发现一般惯用的针筒式帮浦将对微双相流尺寸产生约±20%的尺寸变异，而定压力输入源则能产生尺寸变异系数小於0.73%的均匀微气泡与微液滴。接着透过等效单相流模型分析，成功预测出太极涂布法必要之段塞流模态的操作区间，并找出影响此操作区间大小的关键因子：微流管道几何流阻比G*。最後则开发出一可即时控制液气微双相流尺寸变化的闭回路系统，於微液滴和微气泡尺寸的即时控制变化范围可达一个数量级，而整体尺寸操控之误差小於±3%。
II. 液气微双相流即时侦测系统之开发：
本研究共开发出电阻感测器与微光纤感测器两种液气微双相流即时侦测系统。电阻式感测系统透过液体与气体导电程度的差异来辨别彼此，於液气微双相流流速和尺寸的量测误差分别在±1%和±6%范围内，但工作流体限定为导体。微光纤侦测系统则透过工作流体的折射率变化之感测获得气液介面资讯，仅需极微量(100 nL)的检体便可同时进行微双相流折射率、流速与尺寸的即时量测，对折射率、流速和尺寸的量测解析度分别为2 × 10-4、50 μm/s和5 μm，足以应用於太极涂布法之精密定位。
III. 多管道液气微双相流同步产生与涂布机制开发：
本文共研究开发出三种被动式共流体源同步产生液气微双相流的结构。第一种混合T型与梯状微流道设计，利用流体耦合性於双管道中反相产生液气微双相流，且随着两管道中的微气泡越往下游移动，两者间的相位差会逐渐缩小至接近同步，但难以拓展至三管道以上的应用。第二种为双扩展角毛细阀门设计，可於双管道中产生相位相同的液气微双相流，但却有作动频率较慢的问题。第三种则为三平行聚焦型微流道结合下游梯状流道的设计，可於三管道中以高频率产生同相的液气微双相流，且易於平行扩展至多流道。而於多管道液气微双相流同步涂布部分，本研究以哈根-泊肃叶定律为基础，开发出简易控制多管道分流均匀性的技术，可使各管道间分流误差小於±1%。此外，本研究也已成功测试出三平行管道可同步涂布的操作区间，各管间的相位差控制在±4.6º以内。於十管的同步涂布测试中，则能成功产生相位差小於±7.5º的液气微双相流。

并列摘要〈TOP〉

With the growing demand for the rapid changes of consumer electronics, a variety of coating methods have been applied in high-tech industries. Among these coating techniques, pattern coating technology has gradually become the mainstream due to its eco-friendly features. Air-Bubble Coating is a novel mask-less pattern coating method, and it generates discontinuous patterns by continuously coating the segmented gas-liquid micro-two-phase flow onto the substrate. It has superior characteristics such as simple operation, wide viscosity applicable range, and good compatibility to roll-to-roll process. This research aims to grow Air-Bubble Coating into an industrial mass production technique. According to the required key technologies, the structure of this dissertation work is divided into three major parts:
I. The development of real-time size control system for gas-liquid micro-two-phase flow:
First of all, the effect of fluid driven sources on the size uniformity of gas-liquid micro-two-phase flow has been investigated. The commonly used syringe pump would produce about ±20% bubble/droplet size variation while the constant pressure source could generate uniform size of bubbles/droplets with the coefficient of variation less than 0.73%. Second, the operational range of slug flow, which is essential for Air-Bubble Coating, can be well-predicted based on the equivalent single-phase flow model, and the channel geometric factor G* has been identified as the key parameter that affects the scope of slug flow region. Finally, a closed-loop system for controlling the size of gas-liquid micro-two-phase flow in real-time has been developed. The bubble/droplet size variable range of this system reaches one order of magnitude, and the overall size control error is less than ±3%.
II. The development of on-line detection system for gas-liquid micro-two-phase flow:
An electrical resistance sensing system and an optical microfiber sensing system have been developed to on-line detect the gas-liquid micro-two-phase flow. For electrical resistance detection system, the conductivity difference of liquid and gas was applied to identify the gas-liquid interface, and the velocity and size measurement errors were within ±1% and ±6%, respectively. However, in order to operate properly, the continuous phase fluid must be conductive. In contrast, the microfiber detection system obtains the information of gas-liquid interface based on the refractive index change of the working fluid. With only tiny sample volume (100 nL), the on-line detection of refractive index, velocity, and size can be performed simultaneously. The measurement resolution for refractive index, velocity, and size are 2 × 10-4, 50 μm/s and 5 μm, respectively. This optical sensing system is robust enough for the precision positioning of Air-Bubble Coating.
III. The development of synchronization for the generation and coating of multi-channel gas-liquid micro-two-phase flow:
Three microfluidic structures for passively maintaining the synchronicity of gas-liquid micro-two-phase flow generation with common fluid sources have been developed. The first microfluidic structure combines the design of T-junction and ladder channels, and it utilizes fluid coupling to generate out-of-phase gas-liquid micro-two-phase flow in two parallel channels. The phase lag between these two channels gradually approaches zero as the bubbles/droplets flow downstream. However, it is difficult to apply this design to more than two parallel channels. The second microfluidic structure is two capillary valves with dual diffusor. It can produce in-phase gas-liquid micro-two-phase flow in two parallel channels, but the working frequency is much lower than the first design. The third one is a three parallel flow-focusing device with downstream ladder channels. It can generate in-phase gas-liquid micro-two-phase flow between all channels with high frequency, and it is suitable to scale up to multi-channel applications. For the multi-channel coating of gas-liquid micro-two-phase flow, a simple technique has been developed to control the uniformity of flow distribution within parallel channels based on Hagen-Poiseuille's law, and the diversion error is less than ±1%. Furthermore, the operational range for three channel synchronization coating has been investigated. The phase difference between each channel can be controlled within ±4.6º. As for ten parallel channels coating, the phase difference of gas-liquid micro-two-phase flow among all channels was less than ±7.5º.

参考文献 ( 241 ) 〈TOP〉

[2] 林怡君. (2011). 全新式精密图案涂布技术之开发与研究-「太极涂布法」. 博士学位论文, 国立台湾大学, 台湾.
连结：
[10] Liu, Y., Cui, T., and Varahramyan, K. (2003). All-polymer capacitor fabricated with inkjet printing technique. Solid-State Electronics, 47(9), 1543-1548.
连结：
[11] Pudas, M., Halonen, N., Granat, P., and Vähäkangas, J. (2005). Gravure printing of conductive particulate polymer inks on flexible substrates. Progress in Organic Coatings, 54(4), 310-316.
连结：
[12] 潘柏廷. (2010). 精微图案毛细管涂布之研究. 硕士学位论文, 国立台湾大学, 台湾.
连结：
[15] Sirringhaus, H., Kawase, T., Friend, R. H., Shimoda, T., Inbasekaran, M., Wu, W., and Woo, E. P. (2000). High-Resolution Inkjet Printing of All-Polymer Transistor Circuits. Science, 290(5499), 2123-2126.
连结：

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引用含有DOI的文献

DOI可强化引用精确性、增强学术圈连结，并给予使用者跨平台的良好使用经验，目前在全世界已有超过五千万个对象申请DOI。 如想对DOI的使用与概念有进一步了解，请参考 （ ） 。

DOI可强化引用精确性、增强学术圈连结，并给予使用者跨平台的良好使用经验，目前在全世界已有超过五千万个对象申请DOI。如想对DOI的使用与概念有进一步了解，请参考（）。