Production methods for large area printed electronics
Transcript of Production methods for large area printed electronics
31.07.2014 © 2011 COATEMA Coating Machinery GmbH | www.coatema.de 1 31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 1
Thomas Kolbusch, Vice President
Production methods
for large area printed electronics
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 2
Summary
Introduction
Coatema
What does
Printed
Electronics
mean?
Overview on
OPV
Scaling up
new
technologies
Technologies
& processes R&D projects
Upscaling from
Lab to Fab Summary
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 3
Introduction Coatema
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 4
Introduction Coatema
founded
1974
Film/Paper
Printed Electronics
Prepreg
Membranes
Renewables
Textile
Glass
bespoken equipment
working widths
from100 mm
up to 5,400 mm
Fro
m L
ab
2F
ab
R&D projects & network
worldwide service
laminating
coating
printing
inn
ova
tio
ns
quality made in Germay
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 5
Introduction Coatema
Our Headquater in Dormagen
1 Head office
2 R&D centre
3 Assembly hall I
4 Assembly hall II
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 6
Introduction Coatema
Our worldwide service
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 7
Textile Film
Paper
Renewables Prepreg
Membranes Printed
Electronics
Glass
Introduction Coatema
Our markets
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 8
Introduction Coatema
Our customers
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 9
Introduction Coatema
Our latest awards
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 10
Introduction Coatema
Our R&D partners
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 11
Introduction Coatema
Our innovations through times Projects of the last 5 years
ProLiBat Flexensys
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 12
Introduction Coatema
Our know-how
Co-Author: Andreas Giessmann
Chapter: „Anwendungen“
Author: Andreas Giessmann
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 13
Introduction Coatema
Our business units
Lab Pilot Production Custom
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 14
Introduction Coatema
Our R&D centre
Qualified personnel
Laboratories
Testing facilities
1200 qm
12 Pilot plants
1 production line
1 Click&Coat line
Working widths:
100 – 2000 mm
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 15
Introduction Coatema
Our R&D solution
Chemical
solution
Process
solution
Lab
solution
Coatema
solution path
Taylor-made
for your
product idea
Your
inquiry
Lab trials
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 16
Pilot production Standard layouts Bespoken equipment
on big scale Fab system inline
Introduction Coatema
The one stop shop solution Batch type operation R2R on small scale Semi production on
small scale
Custom made
small scale
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 17
What does printed electronics mean?
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 18
What does printed electronics mean?
Definition
Common points for printed Electronics are
High volume and large area device
Lateral and vertical resolution requirements
But different applications have different requirements!
OPV
large area, multilayer film
low thickness tolerance
high uniformity
OTFT
High lateral resolution,
small feature size
high density integration
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 19
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 20
Source: Heraeus, manroland, Infineon, Karl Knauer
Printed Electronics Microelectronics
Chemistry
What does printed electronics mean?
The future market
Printing
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 21
2010 2 Billion US$ predominantly by OLED displays 2012 8 Billion US$ predominantly by OLED displays Potential for a 50 Billion US $ market within the next 10 years driven by OPV, lighting, displays, logic, memory/RFID, sensors
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 22
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 23
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 24
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 25
What does printed electronics mean?
The future market
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 26
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Fra
unhofe
r IS
E
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 27
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Pla
stic L
ogic
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 28
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Hols
t C
entr
e
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 29
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Th
in F
ilm E
lectr
onic
s
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 30
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
pla
stic e
lectr
onic
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 31
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
VA
RT
A M
icro
batt
ery
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 32
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Th
in F
ilm E
lectr
onic
s
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 33
What does printed electronics mean?
The Roadmap 2013
Pic
ture
sourc
es:
Cete
mm
sa
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 34
Scaling up new technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 35
Scaling up new technologies
Scaling up technologies
Flexibility Precision Bespoken
Near to market Scalable Enabling Standardized
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 36
Test Solution
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 37
Test Solution
With Slot Die
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 38
Mini Coater
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 39
Test Solution R2R
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 40
The Easycoater
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 41
The Thin Film Coater & Printer
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 42
The Smartcoater
Lab, Pilot and production tools
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 43
Lab, Pilot and production tools
R2R in nitrogen environment
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 44
Lab, Pilot and production tools
The Basecoater 3rd Generation
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 45
Scaling up new technologies
The Click&Coat
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 46
Upscaling from Lab2Fab
Going to Fab - Technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 47
Scaling up new technologies
Production lines
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 48
The key
The right fit, regarding production speed, accuracy, resolution,
capital investment and cost of ownership determines the market
success of a production value chain for large area printed
electronics.
And a market for the products!
Scaling up new technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 49
The key
Scaling up new technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 50
The key
Scaling up new technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 51
The key
Scaling up new technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 52
Overview on organic photovoltaics
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 53
Overview on OPV
Process Layout for OPV
The common feature is that these solar cells can
can be printed or being coated
CIGS
Cupper indium
gallium
selenide
Small
Molecules
DSSC
Dye sensitized solar
cells
Polymer solar cells
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 54
Efficiency reached today
Overview on OPV
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 55
Hole Transport Layer
Bulk heterojunction with
• Polymer p-type (P3HT)
• Fullerene n-type
(C60 PCBM)
• Aromatic solvents
Conductive solution with
• Conductive polymer
• Matrix material
• Additives
• Co-solvents
Standard structure for OPV
Overview on OPV
Transparent Substrate
Photoactive Layer
Transparent Anode
Cathode
Glass or barrier film
Vapor-deposited metals
(such as Ca, Al, LiF)
Transparent ITO or Metal Oxides
Glass/PET Substrate
Encapsulation
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 56
Hole Transport Layer 80-300nm
Preferred architecture for R2R manufacturing
Conductive solution with
• Conductive polymer
• Matrix material
• Additives
• Co-solvents
Bulk heterojunction with
• Polymer p-type (P3HT)
• Fullerene n-type
(C60 PCBM)
• Aromatic solvents
Inverted structure for OPV
Overview on OPV
Substrate
Photoactive Layer 80-300nm
Hole Transport Layer 30-100nm
Transparent Electrode 50nm-1µm
Anode 50nm-10µm
Cathode
Encapsulation Glass or barrier film
Solution-processed metals
(such as Silver)
Solution-processed ZnOx
Transparent ITO or metal oxides
Plastic film (i.e. PET, PEN)
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 57
Process Layout for OPV
Overview on OPV
Substrate
pre-
treatments
Coating
Curing
Printing
(Patterning)
Curing
(recognation of
transparent
laxer for
registration)
Printing
(in register)
Curing
(recognation
for
registration)
Printing
(in
register)
Curing
Printing
(in register)
Curing
Printing
(in
register)
Printing
(in register)
Lamination
Curing
Cutting
w/o
cracking
(in register)
Process steps of OPV component manufacturing
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 58
It is not only printing or coating
to reach efficiency record modules!
Production chain for modules
Treatment of films
Solvent or waterbased coating lines
Printing Technologies
Dryers and annealing ovens ITO/Pedot/TiO2/Dye apllication systems
Laminators for packaging/encapsulation
Bus bar application lines
Diode setting and soldering Adhesive apllication on films
Encapsulation lines
QM-Systems
Module to substrate bonding
Overview on OPV
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 59
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 60
Technologies & Processes
Overview and Basics
Nano-
imprinting
Laser
Patterning
Encapsulation
Pick &
place
Surface
treatment
Printing Coating
Photo-
lithography
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 61
Technologies & Processes
Process Parameters
Process Parameters are:
Operation speed
Rheology of coating and printing inks
Substrate condition
Tension control MD/CD
Edge control
Resolution and registration accuracy of printing/laminating systems
Precision of coating operations
Curing / drying / crosslinking
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 62
From Lab2Fab
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 63
Inline Process Integration
Tension control
• load cell
• dancer
• pulling devices
• design of drives
Edge guide control
• different sensors
• mechanical stress
Registration control
• camera
• fiber optic
• design of drives
Quality control
• particle contamination analysis
• defect detection
• thickness control
• function control of the device or layer
Process analysis
• Statistic parameters
• product flow analysis
• Yield
• Cost of ownership
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 64
Printing Systems
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 65
Printing Parameters
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 66
Printing Parameters
Printing method Printing
speed
(m/s)
Nip
pressure
(MPa)
Ink
viscosity
(Pa·s)
Layer
thickness
(µm)
Feature
size
(µm)
Regis-
tration
(µm)
Flexography 3 – 10 0,1 – 0,5 0,01 – 0,5 0,04 – 8 40 – 80 20 – 200
Gravure 10 – 16 1,5 – 5 0,01 – 0,2 0,1 – 12 20 – 75 >10
Offset 8 – 15 0,8 – 2 1 – 100 0,5 – 3 25 – 50 >10
Screen printing 2 - 0,1 – 50 3 – 100 75 – 100 >25
Inkjet 1 – 5 - 0,001 – 0,03 0,01 - 0,5,
20 (UV)
10 – 50 <10
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 67
Printing Systems
Screen printing Gravure printing Flexo printing
Printing Systems
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 68
Gravure Printing
Technologies & Processes
Gravure Printing Parameters
Printing Speed 10 - 16 m/s
Nip Pressure 1,5 - 5 MPa
Ink viscosity 0,01 - 0,2 Pa s
Layer Thickness 0,04 - 12 µm
Feature Size 20 - 75 µm
Resolution 10 - 50 µm
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 69
Flexo Printing
Technologies & Processes
Flexo Printing Parameters
Printing Speed 3 – 10 m/s
Nip Pressure 0,1 – 0,5 MPa
Ink viscosity 0,01 - 0,5 Pa s
Layer Thickness 0,1 - 12 µm
Feature Size 40 - 80 µm
Resolution 10 - 50 µm
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 70
Screen Printing
Technologies & Processes
Screen Printing Parameters
Printing Speed 2m/s
Nip Pressure
Ink viscosity 0,1 - 50 Pa s
Layer Thickness 3 - 100 µm
Feature Size 75 - 100 µm
Resolution 10 - 50 µm
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 71
Registration control system
Needed for registration control:
register control camera
individual printing design of register control marks
pulling device to separate the printing process from the
winding/rewinding of the substrate
high precision side movement of printing device individual and
sensitive speed control of printing roller
pulling device in front of 1st printing station
guiding frame in front of 1st printing station
dancing roller
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 72
Registration control system
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 73
Scribing/Patterning Systems
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 74
Laser Patterning System
Technologies & Processes
Flexlas - Hochgeschwindigkeits-Laserverfahren zur Herstellung vollintegrierter flexibler
Solarzellen
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 75
Project consortium
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 76
Objectives
• Roll-to-roll system with integrated laser processes for
manufacturing of organic solar cells
• Industry-ready laser processes: monolithic series
interconnection, edge deletion, encapsulation
• Organic solar cells from laser-based process chain
with 3% conversion efficiency
• Web speed of up to 10 m/min, laser structuring of thin
films with > 10 m/s
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 77
Innovations
• Cost-efficient roll-to-roll production technology by
integration of laser processes
• Application of high power ultra-short pulse lasers for
residue-free ablation without material modification
• Demonstration system with integrated process chain
(Coating, drying, laser structuring)
• Potential for other applications of organic electronics
(RIFD tags, printed electronics, OLED lighting)
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 78
Patterning 1
Insulation Step ZnO-NP
ITO
PET
PET
PEDOT:PSS
P3HT:PCBM
PET
Silver
Patterning 2
Contacting Step
Patterning 3
Insulation Step PEDOT:PSS
P3HT:PCBM
Objectives
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 79
Patterning 1
Insulation Step ZnO-NP
ITO
PET
PET
PEDOT:PSS
P3HT:PCBM
PET
Silver
Patterning 2
Contacting Step
Patterning 3
Insulation Step PEDOT:PSS
P3HT:PCBM
Innovations
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 80
Patterning 1
Insulation Step ZnO-NP
ITO
PET
PET
PEDOT:PSS
P3HT:PCBM
PET
Silver
Patterning 2
Contacting Step
Patterning 3
Insulation Step PEDOT:PSS
P3HT:PCBM
Innovations
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 81
Flexlas Demonstrator
Space for integration of
laser processes IR dryer
Coater
Inertized housing
Coatema Smartcoater system
ILT Process integration
RUB Process development
4Jet Process control
LIMO Optical system
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 82
Integration of laser processes
• Process control: web edge
and scribe detection
• Structuring: eleven scribes
simultaneously for high
througput
• Edge deletion: galvo scanner
for flexibility
• Encapsulation: gap and
transmission welding of
polymer substrates with barrier
function (not shown)
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 83
Acknowledgements
We are grateful for financial support by the Ziel2 program of
North Rhine-Westphalia and the European Regional
Development Fund within the project “Flexlas”.
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 84
Coatema – LUNOVU Cooperation
Technologies & Processes
Roll-to-roll deposition expertise
Printed electronics
Organic thin films
Strong coating application
know how
Laser expertise
Components & systems
System integration
Strong laser application
know-how
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 85
Integration of Laser Processes into Roll-to-Roll
Manufacturing of Organic Electronics
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 86
Laser Technology in Roll-to-Roll Thin Film Processes
Technologies & Processes
processing and ablation of organic
materials/metals/TCO
Edge deletion, scribing, patterning
Stable and reliable processes
User friendly control environment,
no specific laser process expertise
required
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 87
Nanoimprinting System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 88
Nanoimprinting System
Technologies & Processes
Unwinding
Protective film
Alignment
Coating unit
Embossing
unit
Rewinding
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 89
Nanoimprinting System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 90
Nanoimprinting System
Technologies & Processes
SiO2
Highly doped Si
wafer
SiO2 SiO2
Highly doped Si
wafer
Nanoparticle
solution
A B
Highly doped Si
wafer
SiO2
PDMS mold C
Highly doped Si
wafer
SiO2
PDMS mold
80°C
5 Psi D
Highly doped Si
wafer
SiO2
Dried nanoparticles
E
Highly doped Si
wafer
SiO2
Gold
F
140°C
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 91
Soft-Nanoimprint Drum
Rollers for Nanoimprinting
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 92
Hot embossing System
Technologies & Processes
Hot embossing Parameters
Printing Speed 0,1 - 3 m/min
Nip Pressure
Register controlled
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 93
Hot embossing System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 94
Photolithographic System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 95
Photolithographic System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 96
Photolithographic System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 97
Coating Systems
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 98
Curtain Coating Slot Die
Hotmelt Slot Die
Powder
Scatterning Dipping Rotary
Screen
Coating Systems
Reverse
Roll 5 Roller Micro Roller 3 Roller Combi
2 Roller Combi
Engraved
Roller
Case Knife Commabar Double Side Knife
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 99
Coating Parameters
Finishing
Calendaring
Embossing
Slitting
Coating
Processes
Coating systems
Single or Multilayer coatings
Direct coatings
Transfer (indirect) coatings
Substrate speed
Layer Thickness
Coating accuracy
Process control
Process layout
Tension control system
Material guiding system
Inline parameter control
Quality control
Pretreatment
Corona
Plasma
Cleaning
Substrate
Surface tension
Dimension stability
Surface structure
Contact angle
Drying
Convection drying
Contact drying
Infrared drying
Sintering
NIR
High Frequency
UV crosslinking systems
Environment
Humidity
Temperature
Inert Conditions
Coating
Chemistry
Rheology
Viscosity
Viscoleasticity
Type of solvents
Amount of solids
Van der Waals force
Sheer ratio
Adhesion/Cohesion
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 100
Processes
Definition of Coating Systems
Category of
coating methods
Examples of coating
methods belong to the
category
Characteristics
Self-metered - Dip roll
- Nip forward roll
- Reverse roll
Wet thickness is determined
the conditions of the coating
meniscus
Doctored - Mayer rod
- Blade/knife
- Air knife
- Dip & scrape
Post applicator device
determines the wet thickness
Pre-metered -Slot die
- Slide curtain
- Spray
All the ink fed into an applicator
is transferred to the web
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 101
Technologies
Slot Die System
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 102
Slot Die System
Slot Die Coating Parameters
Printing Speed 1 - 100 m/min
Ink viscosity 0,1 - 30.000 Pa s
Layer Thickness 0,2 - 200 µm
Coating accuracy 1 - 5 %
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 103
Slot Die System
OPV slot die Meniscus mode High precision slot die
Technologies & Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 104
meniscus is formed between die lips and substrate
adhesive stabilization of meniscus by die lips
very low minimum flow rate possible
range of rheological parameters limited for stability
Operating a slot die
Slot Die System
Technologies & Processes
Coating roller
Slot
die
meniscus
Distribution
chamber
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 105
Technologies
Slot Die System
fluid
Slot Die Coating capillary stripe widening
typical
distance
100µ or
less
moving substrate or
Slot Die
with
manifold
shim
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 106
Slot Die System
Technologies & Processes
Manifold + Shim + Meniscus guide
=
stripe stabilization by meniscus guide
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 107
Upscaling from Lab2Fab
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 108
Upscaling from Lab2Fab
Going to Fab
Needed for success:
• Reproducible results in every step of scale?
• Reality check if the approach is really scalable?
• Is the approach an approach for the real life production environment
or is it rocket science?
• Are economies of scale reachable and when?
• Are there existing production technologies which could be used for a
benchmark analysis?
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 109
Technologies
Upscaling from Lab2Fab
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 110
Going to Fab - Technologies
Upscaling from Lab2Fab
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 111
Upscaling from Lab2Fab
Going to Fab - Technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 112
Upscaling from Lab2Fab
Going to Fab - Technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 113
Upscaling from Lab2Fab
Going to Fab - Technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 114
Upscaling from Lab2Fab
Going to Fab - Technologies
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 115
Upscaling from Lab2Fab
Summary
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 116
There are challenges ahead in Europe, but:
The industry has to define processes and standards.
Funding for industrial upscaling is needed.
It is a new value chain, the players have to find together.
A joined cluster approach is needed and takes place.
There is a global effort on PE, this Europe should not forget.
We need global networks, like the OE-A and it's LOPE-C.
It will not be the big ones, the SME's are the strength of Europe.
„Local production on demand versus everyone's big scale“
Summary
Processes
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 117
COATEMA Coating Machinery GmbH
Roseller Str. 4
D-41539 Dormagen
021 33 / 97 84 – 0
[email protected] THANK
YOU
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 118
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 119
Cooperation as a key of sucess
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 120
Partners
Allflex Folienveredlung GmbH & Co KG
production of packaging foils
Interactive Wear AG
and Lodenfrey Service GmbH
production of smart textiles and clothing production
Leclanché Lithium GmbH
battery supplier
Flexensys Project
R&D Projects
Coatema GmbH
supplier of coating lines
ESYS GmbH
supplier of circuit systems
Fraunhofer Institute for Solar energy
research institute
Spree Hybrid & Kommunikationstechnik GmbH (SHK)
data logger and software technology
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 121
Li-Ion Accumulator
robust & flexible
Load electronic & data logger
energy consumption ca. 10mW
Project idea
development of a flexible energy systems for energy autarc micro systems
Demonstrator
energy autarkic sensor system
including data logger,
integrated in a Outdoor jacket
Organic solar cells
low weight & high flexibility
Flexensys
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 122
Data logger
Readout of data Integrated solar cells
Battery
Flexensys
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 123
Facess, FP7
R&D Projects
VTT Finland
Suntrica Finland
Cea France
Coatema GmbH Germany
Warsaw University Poland
Umicore Belgium
Imec Belgium
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 124
4 printed organic solar modules • PCE 2.3% @ 15.5 cm2 @ AM1.5 / module
• Voc 4.6 V, Isc 1.1 mA/cm2
Printed rechargeable Li battery
• 36 mAh @ 36 cm2
Thinned control transistor chip
• 30 µm thick, flip chip bonded
Rotary screen printed backplane
ZigBee radio module
optimized for
printed battery:
Facess, FP7
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 125
Facess, FP7
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 126
Flexensys
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 127
Roll-to-Roll processing of flexible
OLED for lighting applications
R&D Projects
Dr. Christian May, Dr. Stefan Mogck
Fraunhofer IPMS - Center for Organic Materials and Electronic Devices Dresden COMEDD
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 128
OLED Lighting by commed
@ Luminale 2012
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 129
• 300 mm web width
• Metal strips up to 500 μm thickness
• Polymer webs from 50 to 500 μm thickness
• Transportation speed between 0.01 - 1 m/min
• Vacuum evaporation of metal and organic
materials
• Reactive magnetron process of Al2O3 for pre-
encapsulation (full TFE in cooperation with
Fraunhofer FEP)
• Inert transfer between systems
(vacuum lamination)
• An inert box to process under protective
atmosphere for encapsulation and coating with
moisture and oxygen sensitive materials
• R2R inspection system to control defect level
OLED R2R R&D Line at comedd
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 130
14 Linear Organic Evaporators
DC-Magnetron
Lineare Ion Source
2 Metal Evaporators
Substrate Winder
Interleaf Winder
Port for Inert
Substrate Load
Lock
cathode
EBL
HBL
EML
red EML
green
EML
blue
HTL
ETL
BL
BL
Substrate with
Anode layer
3-color-white
OLED stack
R2R vacuum coater MB300-RC
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 131
Attachement possibility for an inert shuttle
Winding unit
Deposition cylinder
Images R2R vacuum coater
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 132
Dogging of the mobile box at the loadlock vacuum coater
To keep the roll under protective atmosphere after OLED process
Roll transfer out off the roller
bearings
Mobile inter Roll Transfer
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 133
• Functionalization of the substrate surface by
coating processes and encapsulation of
organic devices with e.g. a barrier foil
• Encased in an inertbox to process under
protective atmosphere
• Printing and coating with moisture and
oxygen sensitive materials possible
• Gravure printing and slot die coating
• Web inspection system for layer-on-layer
lamination
• Thermal and UV light curing possibility
• Substrate lamination with edge (cartridge)
and area (hot-melt) encapsulation
gravure printing
slit coating
encapsulation unit
R2R Lamination & coating unit
under inert atmosphere
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 134
Inertbox is air tight and prepared for the docking of the mobile box
inert roll transfer from the R2R
vacuum tool
R2R Lamination & coating unit
under N2 atmosphere
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 135
gravure cylinder
Passivation with a white isolating layer to
electrically separate the anode (substrate)
an the cathode.
Patterning of a conductive web with
a dielectric paste
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 136
hotmelt area glue
coating
edge encapsulation by barrier glue
(adjustable for different layouts)
heating cylinder Inert transfer
between vacuum
and lamination tool
possible
Encapsulation by R2R Lamination
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 137
Electrical tests after the encapsulation
Electrical tests in the inert box
OLED operation tests under inert
conditions and after Lamination
R&D Projects
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 138
R2R Inspection System R2R Printing and Lamination Unit under inert conditions
R2R Vacuum Coater
Summary process flow R2R R&D line
Upscaling from Lab2Fab
Vacuum coating
Encapulation OLED characterisation
Substrate inspection
Structuring Substrate inspection
31.07.2014 © 2014 COATEMA Coating Machinery GmbH | www.coatema.de 139
• High efficient and stable top emitting OLED on metals substrates are possible
• R2R OLED line have been successfully upgraded for OLED on polymer films
• R2R printing and lamination under protective nitrogen atmosphere in operation
• R2R inspection unit allows to identify process and defect issues
Summary & Outlook
R&D Projects
Outlook
• Development of white OLED stack in R2R deposition process for general lighting
• Optimization of the Roll-to-Roll process integration: cleaning, patterning, lamination
• Particle- and OLED device controls of the entire R2R OLED process line
• Extension of OLED lighting on flexible TCO coated plastic films