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Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer

This paper presents an integrated high temperature ultrasonic transducer (HTUT) on a sensor insert and its application for real-time diagnostics of the conventional hot embossing process to fabricate V-cut patterns. The sensor was directly deposited onto the sensor insert of the hot embossing mold b...

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Autores principales: Cheng, Chin-Chi, Yang, Sen-Yeu, Lee, Dasheng
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2014
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4239892/
https://www.ncbi.nlm.nih.gov/pubmed/25330051
http://dx.doi.org/10.3390/s141019493
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author Cheng, Chin-Chi
Yang, Sen-Yeu
Lee, Dasheng
author_facet Cheng, Chin-Chi
Yang, Sen-Yeu
Lee, Dasheng
author_sort Cheng, Chin-Chi
collection PubMed
description This paper presents an integrated high temperature ultrasonic transducer (HTUT) on a sensor insert and its application for real-time diagnostics of the conventional hot embossing process to fabricate V-cut patterns. The sensor was directly deposited onto the sensor insert of the hot embossing mold by using a sol-gel spray technique. It could operate at temperatures higher than 400 °C and uses an ultrasonic pulse-echo technique. The ultrasonic velocity could indicate the three statuses of the hot embossing process and also evaluate the replication of V-cut patterns on a plastic plate under various processing conditions. The progression of the process, including mold closure, plastic plate softening, cooling and plate detachment inside the mold, was clearly observed using ultrasound. For an ultrasonic velocity range from 2197.4 to 2435.9 m/s, the height of the V-cut pattern decreased from 23.0 to 3.2 μm linearly, with a ratio of −0.078 μm/(m/s). The incompleteness of the replication of the V-cut patterns could be indirectly observed by the ultrasonic signals. This study demonstrates the effectiveness of the ultrasonic sensors and technology for diagnosing the replicating condition of microstructures during the conventional hot embossing process.
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spelling pubmed-42398922014-11-21 Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer Cheng, Chin-Chi Yang, Sen-Yeu Lee, Dasheng Sensors (Basel) Article This paper presents an integrated high temperature ultrasonic transducer (HTUT) on a sensor insert and its application for real-time diagnostics of the conventional hot embossing process to fabricate V-cut patterns. The sensor was directly deposited onto the sensor insert of the hot embossing mold by using a sol-gel spray technique. It could operate at temperatures higher than 400 °C and uses an ultrasonic pulse-echo technique. The ultrasonic velocity could indicate the three statuses of the hot embossing process and also evaluate the replication of V-cut patterns on a plastic plate under various processing conditions. The progression of the process, including mold closure, plastic plate softening, cooling and plate detachment inside the mold, was clearly observed using ultrasound. For an ultrasonic velocity range from 2197.4 to 2435.9 m/s, the height of the V-cut pattern decreased from 23.0 to 3.2 μm linearly, with a ratio of −0.078 μm/(m/s). The incompleteness of the replication of the V-cut patterns could be indirectly observed by the ultrasonic signals. This study demonstrates the effectiveness of the ultrasonic sensors and technology for diagnosing the replicating condition of microstructures during the conventional hot embossing process. MDPI 2014-10-17 /pmc/articles/PMC4239892/ /pubmed/25330051 http://dx.doi.org/10.3390/s141019493 Text en © 2014 by the authors; licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Cheng, Chin-Chi
Yang, Sen-Yeu
Lee, Dasheng
Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title_full Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title_fullStr Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title_full_unstemmed Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title_short Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer
title_sort novel real-time temperature diagnosis of conventional hot-embossing process using an ultrasonic transducer
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4239892/
https://www.ncbi.nlm.nih.gov/pubmed/25330051
http://dx.doi.org/10.3390/s141019493
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