Improved fine layer patterning using soft blanket gravure printing technology

We have developed a "Soft Blanket Gravure" (SBG) printing technology that can form patterns onto curved or three-dimensional solid surfaces using functional ink. In SBG printing, a soft and thick blanket (called a "Soft Blanket") is employed in the similar process to conventional gravure offset printing processes. We found and reported that SBG printing could completely receive silver ink from printing plates and transfer it to target substrates more effectively than conventional gravure offset printing under various conditions. In this research work, we measured the swelling ratio of the Soft Blanket using two different organic solvents and performed SBG printings using printing plates with groove depths of 10–100 µm and two silver inks that contained the two different solvents. SBG printing could form patterns with thickness of more than 11 µm and the same widths as the grooves on the printing plate (50 µm) using the optimal ink solvent. We also observed that the Soft Blanket could receive silver ink from grooves without cobwebbing, in contrast to conventional blanket. These results indicate that the SBG printing technology significantly improves the printing process because the Soft Blanket can absorb more solvent from silver ink.