Modeling of adhesion dynamics in roll-to-roll lamination processes

Abstract

Roll-to-roll (R2R) lamination is a continuous manufacturing process essential for producing multi-layered flexible products, such as flexible electronics, solar cells, and composite materials. This process allows for high-speed bonding of materials under controlled conditions, making it critical for efficient and scalable production in various industries. This paper examines the R2R lamination process, analyzing how bonding temperature, compression force, and lamination speed affect adhesion between layers. Using a physics-based approach and the Hertzian contact theory, we developed a process model to predict the adhesion force. Experiments were conducted to validate the model. Findings from this research provide insights for future process optimization of R2R lamination processes