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In this paper, we will report our achievements in developing large areapatterning of multilayered ceramic green composites using roller embossing. Theaim of our research is to pattern large area ceramic green composites using amodified roller laminating apparatus, which is compatible with screen printingmachines, for integration of embossing and screen printing. The instrumentationof our roller embossing apparatus, as shown in Figure1, consists of roller 1and rollers 2. Roller 1 is heated up to the desired embossing temperature ;roller 2 is, however, kept at room temperature. The mould is a nickel templatemanufactured by plating nickel-based micro patterns (height : 50 $\mu$m) on anickel film (thickness : 70 $\mu$m) ; the substrate for the roller embossing isa multilayered Heraeus Heralock HL 2000 ceramic green composite. Comparing withthe conventional simultaneous embossing, the advantages of roller embossinginclude : (1) low embossing force ; (2) easiness of demoulding ; (3) localizedarea in contact with heater ; and etc. We have demonstrated the capability oflarge area roller embossing with a panel size of 150mmx 150mm on the mentionedsubstrate. We have explored and confirmed the impact of parameters (feed speed,temperature of roller and applied pressure) to the pattern quality of rollerembossing. Furthermore, under the optimized process parameters, wecharacterized the variations of pattern dimension over the panel area, andcalculated a scaling factor in order to make the panel compatible with otherprocesses. Figure 2 shows the embossed patterns on a 150mmx 150mm green ceramicpanel.

Large Area Roller Embossing of Multilayered Ceramic Green Composites