R2R PRINTING OF ORGANIC AND INORGANIC MATERIALS · 2013-10-07 · R2R PRINTING OF ORGANIC AND INORGANIC MATERIALS Dr. Raimo Korhonen Technology manager Printed Functional Solutions

R2R PRINTING OF ORGANIC AND INORGANIC MATERIALS

Dr. Raimo KorhonenTechnology managerPrinted Functional Solutions Knowledge CenterMicrotechnologies and ElectronicsVTTEmail: [email protected].: +358-40-7030052

Workshop - Graphene for Future Emerging TechnologiesOctober 18, 2011 Madrid

231/10/2011

Outline

Introduction

Technology basis, materials and processes

Application examplesPrinted OLEDPrinted OPVEcological HologramsActive PaperDiagnostic testsWide area sensingPrinted hybrid systems

Routes to commercializationPrintoCentCOLAE

Summary

© VTT 2011 – All rights reserved

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VTT Group in briefTurnover 292 M€ (2010) Personnel 3,167 (1.1.2011)

VTT’s operationsResearch and Development Strategic Research Business Solutions IP Business Group ServicesVTT’s companiesVTT Expert Services Ltd (incl. Labtium Ltd, Enas Ltd) VTT Ventures Ltd VTT International Ltd VTT Memsfab Ltd

Focus areas of researchApplied materialsBio- and chemical processesEnergyInformation and communication technologiesIndustrial systems managementMicrotechnologies and electronicsServices and the built environment Business research

Customer sectorsBiotechnology, pharmaceutical and food industriesElectronicsEnergyICTReal estate and constructionMachines and vehiclesServices and logisticsForest industryProcess industry and environment

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Printed intelligenceStarting idea

• New technology driven disruptive innovation at the cross sections of the paper and electronics industries:

• manufacture electronic components utilizing roll-to-roll production techniques – printed electronics

• printing of new functionalities into high volume low cost packaging and printed media applications – printed functionality


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Printed Intelligence

The vision is to create easy to use and cost effective products based on sensing, light emitting surfaces, energy foils, optical films and electrical circuits by using printing methods.


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VTT Printed Intelligence

is a growth oriented strategic VTT wide initiativecombines multidisciplinary know-how

electronics, optics, biotechnology, nanotechnology, chemistry, printing, P&P, process automation

strong established partnership network to research and industryorientation towards applications and business

technology | applications | business

Project modelate 90s -

Various projects throughout VTT

Strategic research program

2006 – 2009Building the basis for

a new technological opening

Commercializationstage2010 -

Introduction of technologiesfrom lab to early markettrials and commercial

adoption

VTT organization and printed intelligence – stages of development:

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Outline

Introduction




Summary


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Printed Intelligence Is Based on…

fluid processable materials technology

large area high-volume printing like mass-manufacturing methods

functionality from electronics, biotechnology, chemistry, optics, optoelectronics, etc. integrated as devices and systems

Generic, enabling technologies

Patterning, devices, integration, systems-on-foil, embedding'electronics’ into products

R2R to hybrid processes & production equipment

Materials

+ possible interconnections of printed systems to wider IS/IT-systems

Impression roll

Printing rollDoctor blade

Ink

Film

Impression roll

Printing rollDoctor blade

Ink

Film


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New uses for existing materials New advanced materials in liquid phase:

conductive polymers and particulate inks organic and inorganic semiconductors nano-materials (nanotubes, low melting Ag, etc)bioactive materials

High volume disposable applications demand biodegradable materials

Generic, enabling technologies

Components, circuits, integration-on-web, systems-on-foil, embedding 'electronics from inks' into products

R2R to hybrid processes & production equipment

Materials

A major share of current printed intelligence R&D activity and money is in the development of materials

Materials


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Materials

Functional inks are key. In many cases special formulations needed.New skills and equipment required in printing / converting process.Quality control !!!

Commercial ink Modified ink

Bad chemistry

Good chemistry

Traditional inks & printing

Functional inks


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R2R Gravure-, flexo-, and screen-printingR2R hot-embossingInk-jet for individualizationR2R Laser processingR2R Lift-offR2R etching

Functional ink formulationDevelopment of the printing toolsOn-line characterizationPilot scale production

High Volume Cost Effective Production with Roll-to-Roll Processes


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4 replaceable printing units- Direct and reverse gravure, rotary

screen, and flexography unitsCorona and lamination unitsDrying units (air, UV, IR)Web width 300 mm Max. web velocity 10 m/min

2 gravure printing unitsR2R hot embossing unitCorona and lamination unitsDrying units (air, UV, IR)Web width 200 mm Max. web velocity 100 m/minInstalled in clean room (ISO7)

PICO 2003 ROKO 2007 R2R laser facility

Lumera Rapid ps-ablation laserOther lasers

- CO2

- Eximer- IR-diode- ND-YAG

R2R pilot lines at VTT


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R2R Inert atmosphere printing pilot line2 interchangeable printing unit slots (possibility add third later)

forward gravurerotary silk screen

Lamination unitDrying units (IR)Manual registration systemPrinting, curing and lamination made in nitrogen atmosphere (O2 level below 1%)Max. web width 300mmMax. web velocity 20m/min

Developed in FP-7 project FACESS in collaboration with Coatema

Unique facility for processing of oxygen and moisturesensitive components (like OLEDs, OPVs) in pilot scale

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Thermal nanoimprinting litho - hot-embossingMechanical structures are embossed

under pressure and heat on plastic webEmbossing cylinder

• Ni-shim• Laser or e-beam fabricated

Features sizes• Horizontal: ~100 nm at minimum• Vertical: <50 nm - 50 µm

Plastic web

Pressure roll

Hot-embossing roll

Pressure roll

Embossing roll

HeatHeat


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Inkjet research environment and capabilities

Inkjet deposition process & application development

Functional fluid development and jettability optimizationSubstrate surface optimizationUnderstanding of material interface interactionsMultilayer device fabrication process developmentSimulation of industrial XY or R2R fabrication process

by using industrial multinozzle printheads

Printed layer/device characterization

2D/3D imaging of fabricated layersPerformance characterization of devices

High accuracy inkjet deposition printers

Dimatix Materials Printer DMP-2831Microdrop Autodrop Professional MD-P-801iTi XY-MDS2.0/Apollo II PSK driving industrial

FUJIFILM Dimatix printheads

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Outline

Introduction


Application examples

Routes to commercialization

Summary


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Passive and active electronicsPassive electronic components

- Conductor, resistor, coil, capacitor, antennas etc.- Multilayer structures, flexible PCB- Simple circuits, RC high and low pass filters

Fabrication of active electrical components- Diodes, Transistors- Simple circuits, passive elements (resistors,

capacitors etc.), sensors

Materials- Semiconductors (PQT, P3HT etc,)- Conductors: PEDOT:PSS, polyaniline (PANI),

commercial Ag- and or C-based inks- Commercial Insulators

Gravure-printed passive and active components

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Solution processed inorganic transistors

• ZnO precursor approach• Devices annealed in ambient air at 150 °C• No encapsulation• High on/off-ratio 104

• µinc ~ 1.2 cm2/Vs • µsat ~ 0.2 cm2/Vs

Sideview of the TFT structureSEM of the ZnO layer.

Top view of a bottom-gate TFT

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R2R manufactured OLED rollFP6-2003-IST-2-004315


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RFID powered OLED

The development of wireless powered OLEDsFlexible, light weight and thin configuration


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Organic solar cells

Gravure printed OSCs on flexible ITO-PET substrate• Gravure printed PEDOT (air processing)• Gravure printed P3HT:PCBM (air processing)• Evaporated cathode• All R2R process during 2011

+-

ITOPEDOT:PSS (30 nm)

P3HT:PCBM (150 nm)

PET/PEN

Cathode (Ca/Ag)

Voc = 0.61 VIsc = 5.41 mA/cm2

FF = 0,52= 2.82 % (AM1.5 reference)


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Grafene coated Ni nanoparticle ink for silk screen printing of porous metal conductor layer in novel dye

sensitized solar cell (DSSC) structure

Needs for printed metal

nanoparticle ink

Conducting(no oxidation of the nanoparticles)

Porous to allow electrolyte flow through the printed conducting layer

Printable for silk screen technique

Testing of printed porous metal layer in all-silk-screen-printed

DSSC

In-house formulation

of conducting

silk sreen ink

In-house synthesis of

grafene coated

nanopartidle synthesis

More information: [email protected] or [email protected]

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Printed sensors

Resistive sensors• Strain gauge

Capacitive sensors• Pressure• Moisture

Chemical sensors• Gas sensors• Liquid sensors

Challenges• Accuracy• Stability• Selectivity

Benefits:• Cost efficient, highthroughput production• Flexible, thin• Large area

Printed piezo sensor

Large area strain gauge

Gas sensor

Gravureprinted WO3nanoparticlelayer

Electrodes

Active area

Moisture sensor structure

Antenna

Matching circuit

Sensing area


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R2R manufactured MEMS colour filter

Development of roll-to-roll manufacturing process for large area MEMS displayBased on Fabry-Perot structureColor of white back light is changed using F-P cavityAdvanced R2R fabrication process:

• Gravure, screen printing• Laser processing• Hot embossing• Lamination

Funded by:• NEDO, Japan• TEKES, Finland

3x3 pixel demo

20x40 pixel demo© VTT 2011 – All rights reserved

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Questionnaires, marketing games, customer feedback, ... Memory by VTT based on electrical sinteringCircuitry and assembly on paperboard by Stora EnsoBattery by EnfucellReadout with a contact reader or using a Nicanti reader

LED write indicator

WORM memory bank R2R printed on VTT ROKO

connector slip for answer readout using a contact reader

PriMeBits Electric Memory Card

Answering buttons


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Hologram Products

Transparent or printed material with holographic effects

Transfer images with holographic effects

Patent pending

Holographic moisture indicator

Patent pending


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Bioactive paper

Novel products in rapid diagnostics in the areas of

health wellbeing environment

Additional features to packaging, labelling or other paper products

The technology also presents new possibilities for ensuring product authenticity and impeding falsification.

Negative Positive

Printed test on specially developed paper

Printed fluid guiding channels in paper


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Requirements for Biosensors

Sample deliverySample handling Sample transportAnalyte detectionQuantificationLow costTest time

ReproducibilityStability SensitivitySelectivity

Sensing layer• high surface density / binding activity• oriented immobilization• low nonspecific binding • stability for long-term use

NegativePositive

Measurement

Result

MULTIANALYTE POC SENSOR

Coupling grating

Biochemical sensitive optical waveguides

Analyse

YSensing

layer

Sampledelivery &handling

Waste reservoir

fluidicchannel

Y YYY

Detection

2931/10/2011

Demonstrated FeaturesFully enzymatic fuel cell

lifetime currently ~1 weekpower level in the order of 0.1 – 0.3 µW/cm2

thickness 0.5 mm, cell weight 120 mg/cm2

open cell voltage: at least 0.4 V constant current output: 5 µA momentary current output (100 ms): 100 µA/cm2

voltage increased by series connection

Enzyme-based cathode with Zn anodeopen cell voltage: 1.6 V

General featuresDisposability, the use of renewable catalysts and possibility for series production (printability)Pat.Pending

Printed Biofuel Cells (BFC) based on printed enzymatic catalysts

Oxidized substrate ElectronsElectrons

Anode CathodeSubstrate

(sugar or alcohol)

O2

H2O

LaccaseH+

Membrane

e.g. FDH, MDH

3031/10/2011

Printed Hybrid SystemsFlexible and printed electronics- Plastic Integration

Printed Hybrid Systems are components and systems which:Combine printed intelligence and non-printed components and subsystems in order to optimise both performance and costIntegrate several manufacturing processes

Key Technologies:Multi-layer polymer foil hybrid systems:

Flexible electronicsPrinting technologies and materials Multi-layer laminationChip bonding & embedding

Foil over-moulding: In-Mould-Labelling • Injection moulding

Key Drivers & Benefits:Low cost packaging, integration and 3D system miniaturization with polymers, high through-put manufacturing and simpler value chainEnhanced functionality embedding, convergence and freedom of design (electrical, mechanical, optical, sensing, actuation, power …)Flexible, light, thin, large-area and low-cost conformal integration

3131/10/2011

Outline

VTT Group

Introduction to Printed intelligence




Summary


3231/10/2011

Centre for business development in the area of Printed Intelligence.

Offers a world-class pilot production environment based on Printed Intelligence processes.

Brings together complementary players across the value chain - ranging from technology providers to customers.

Customer Affiliate Programs.

www.printocent.com

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Pilot Factory (2011)

4 interchangeable printing unit slotsforward gravurereverse gravurerotary silk screenFlexographyslot die coating

Hot embossing unitPlasma substrate treatment unitLamination unitRotary die cut unitDrying units (air, UV)Automatic registration systemMax. web width 300mmMax. web velocity 30m/min Possibility to add two more unit slots, more oven capacity, laser unit and inkjet unit later

Pilot manufacturing facility for ramping-up production

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EC-FP7 project: Commercialization Clusters of Organic and Large Area Electronics (COLAE)

To activate European OLAE clusters to an European level cooperation in commercialization of Organic and Large Area Electronics (OLAE)From technology push to market pull in OLAEStrong emphasis on

Creation of awareness in potential application areas Presentations at trade shows, B-to-B seminarsWorkshops targeting to industrial designers Direct contacting to brand –owners (LSEs) and SMEs

Starting of training activities for company personnel Development of sustainable operation model for clusters and their services, so called `OLAE Foundry` -concept

17 partners, budget 3.8 M€, 3 yearsCoordinator: VTT, Mr. Ilkka KaistoKick-off Sept. 21, 2011

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Outline

Introduction



Routes to commercialization

Summary


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Summary: Emerging Business Opportunities In Printed Intelligence

rokomeasurement.wmv

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Acknowledgements

TEKES, EU FP6 & FP7, Academy of Finland, European Union Regional Development Fund, State Provincial Office of Oulu, Council of Oulu Region, City of Oulu and Industry for financial supportPrintoCent collaborators

Research partners & Industrial collaborators

Co-workers throughout VTT working on a range of printed intelligence developments

New annual report 2010 on VTT’s printed intelligence activities:www.vttprintedintelligence.com

3931/10/2011

VTT creates business from technology

Documents

R2R PRINTING OF ORGANIC AND INORGANIC MATERIALS · 2013-10-07 · R2R PRINTING OF ORGANIC AND INORGANIC MATERIALS Dr. Raimo Korhonen Technology manager Printed Functional Solutions