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PETECThe Printable Electronics
Technology Centre
Copyright CPI 2011. All rights reserved
Printable Electronics:
New Products and Opportunities for North
East Companies
PETECThe Printable ElectronicsTechnology Centre
Agenda
• What are ‘Printable Electronics’?
• How big is the Opportunity?
• What are the Manufacturing Challenges?
• How do companies in the North East benefit?
PETECThe Printable ElectronicsTechnology Centre
What are ‘Printable Electronics’?
Printed electronics (also called organic electronics or polymer electronics)
Nothing to do with organic food or alternative lifestyles!
+ +
“Organic” refers to electronics based on carbon chemistry, instead of conventional silicon. Organic electronics can be printed in a cheaper, greener process
PETECThe Printable ElectronicsTechnology Centre
What are ‘Printable Electronics’?
• Components of Plastic Electronics– Organic molecules and polymers:
• Semi-conducting or light-emitting properties;
– Inorganic materials• Metal nanoparticles / Metallic inks
– Wide variety of substrates (application-specific)
• Process technologies • Traditional high-technology manufacturing industries (such as
liquid crystal displays)• Printing industries.
PETECThe Printable ElectronicsTechnology Centre
What are ‘Printable Electronics’?
• The organic electronic materials are often polymers which can be dissolved and printed using the basic processes of the printing industry.
• This gives rise to the prospect of manufacturing electronic circuits using low-cost printing processes on any substrate surface, whether rigid or flexible.
• It will lead to the creation of a whole new range of products such as conformable and rollable electronic displays, large-area efficient lighting and low-cost solar cells.
PETECThe Printable ElectronicsTechnology Centre
What are ‘Printable Electronics’?• A lot of the prototypes in labs or commercial products
using the technology actually mix the organic and inorganic technologies to create hybrid devices e.g.
• Organic components with inorganic conductors.– Inorganic conductors can be printed as inks which contain
nano-sized particles of silver that sinter into conductive tracks when heated.
Print using Ink Jet or other Print Technologies:
Printed Electronics
Print on a flexible substrate (plastic
foil):Flexible
Electronics
Build devices from layers of deposited / printed thin films:
Thin Film Electronics
Print large areas:Large Area
Electronics / Organic Large
Area Electronics
PETECThe Printable ElectronicsTechnology Centre
What are ‘Printable Electronics’?
• Plastic electronics• Printed electronics• Organic electronics• Thin film electronics• Flexible electronics• Large Area electronics
PETECThe Printable ElectronicsTechnology Centre
How to Make Printable Electronics
© Solarcon
© Flisom
© Sony© Digital Trends
Start with base materials
Metallise contactsPrint semiconductor and insulator layers
Makes a “backplane” of pixels
Print light emitting “OLEDs”
Add driver circuitry
Encapsulate and protect
Package and driver circuitry
PETECThe Printable ElectronicsTechnology Centre
Different to conventional electronics!• Flexibility• Lower transistor speed (no plastic
Pentium, but good for some applications)
• Semiconductor can be printed from ink – potential for volume printing
• Potential to avoid expensive vacuum process steps
• Potential to avoid expensive high temperature process steps
• Ability to print transparent devices• …… but still links to conventional
electronics, (driver circuitry, printed functionality)
© Coatema
© Photobucket
PETECThe Printable ElectronicsTechnology Centre
Applications
© Dupont
© TheMajorLearn
© Plastic Logic © Photobucket
© Solarcon
© Toppan
© PolyPhotonix
© Molecular Vision
© Novalia
© Polyphotonix
Solar Cells
Art
Solid State Lighting
Toys
MedicalSmart CardsSecurity
Smart Textiles
Display Screens
E-Books
PETECThe Printable ElectronicsTechnology Centre
Petec’s Key Technology Areas
© Visionox © Sony
© GE © Thorn
© Flisom© UniSolar© Aveso © Molecular Vision
PETEC Process and Materials
Technologies
Flexible Displays
Solid State Lighting (SSL)
Solar Cells
Integrated Smart Systems (ISS) and Sensors
PETECThe Printable ElectronicsTechnology Centre
Technology overviews
• Displays– OLED Displays– Electrophoretic Displays– Touch Screen Technologies
• Solid State Lighting• Organic Photovoltaics
– Barrier• Integrated Smart Systems
PETECThe Printable ElectronicsTechnology Centre
Displays
• There is a lot of activity in this area mainly because the end markets are real and of high value (e.g. flat screen TVs and e-readers).
• It’s fair to say that most progress has been made in this area and a number of test products are on the market
PETECThe Printable ElectronicsTechnology Centre
Organic components for displays
• Organic Thin Film Transistors– Materials for device development (semiconductors, binders
etc)– Used for driving a display
• Organic LED– Used to create the images
• Common to these two– Cost of materials and process– Lifetime/stability– Flexibility
• Substrates
PETECThe Printable ElectronicsTechnology Centre
Organic Light Emitting Diode (OLED) Displays
• OLEDs are made from light-emitting polymers and emit light when an external voltage is applied.
• They require only a small amount of power and they are made as thin films using printing techniques.
• They can also be printed on flexible substrates (e.g. plastic foil).
PETECThe Printable ElectronicsTechnology Centre
Organic Light Emitting Diode (OLED) Displays
• Consequently, OLEDs can be used to make flexible displays, which could be relatively inexpensive to manufacture.
• A lot of resource is being applied to the development of these displays for use in commercial products because OLED technology is now efficient and robust, and the end-use markets are large and well understood.
PETECThe Printable ElectronicsTechnology Centre
• 7 layers, 48,000 pixels, fan out to 200 x 240 pads
• Test Element Groups (TEGs) for:– OTFT (after stages 2,5,7) and
in groups of 10
– VIA chains
– Serpentines
– Capacitors
• Process takes ~2 days beginning to end
OTFT Backplane
PETECThe Printable ElectronicsTechnology Centre
OTFT Backplane
• 106ppi e-paper backplane
• Produced on a glass substrate
• 6 micron minimum feature, 5 micron design rule (overlay accuracy)
• 3” (75mm) diagonal, 48,000 transistors
0.1mm
1cm
1mm
PETECThe Printable ElectronicsTechnology Centre
OTFT Backplane
OTFT Backplane (PETEC)
Frontplane lamination (ASU)
Drive electronics (“E-ink broadsheet kit” via ASU)
Row/column driver chips (subcontract via ASU)
Flexible connector “tape” (subcontractor via ASU)
Complete e-ink display demo
PETECThe Printable ElectronicsTechnology Centre
Touch Screen Technologies
• IMS Research hold a comprehensive course on these technologies
• Opaque touch– Dominated by the controller chip suppliers
• Atmel, Cypress, Synaptics, etc.• One technology (projected capacitive)• Sensor is typically developed by the device OEM
• Notebook touchpads are the highest-revenue application– Synaptics ~60% share; Alps ~30% share; Elan ~10% share– Sensors are all two-layer projected capacitive
• Transparent touch on top of a display– Dominated by the touch module manufacturers– (100+ worldwide)– 13 technologies
PETECThe Printable ElectronicsTechnology Centre
Touch Screen Technologies by Materials and Processes
© Source: IMS Research 2011
PETECThe Printable ElectronicsTechnology Centre
Solid State lighting – Material Choice
• Polymer OLED– Complicated, expensive
material synthesis– Then cheap
manufacturing (spin coating or printing)
– Examples PPV-MEH
• Small Molecule OLED– Cheaper, easier material
synthesis– Then expensive vacuum
deposition– Examples are chelate
metal complexes, e.g. ruthenium bipyridine
Two main routes – “polymer” and “small molecule”Two main routes – “polymer” and “small molecule”
© Philips
PETECThe Printable ElectronicsTechnology Centre
First versions from universities in 1987
Commercially available for very leading-edge applications (Sony TV)
OLEDS: Examples
Sony XEL-1
© Philips
© GE
© GE
© Sony
© Ellumin8
PETECThe Printable ElectronicsTechnology Centre
Advantages / Disadvantages of OLED
• Positives
• Low power, can run from batteries
• Tunable colours• High efficiency• Bright• Can be made on flexible
surfaces• Can be made thin• Can be large area
• Negatives
• Lifetime!!!
• Currently expensive, as:– Technology is in its infancy,
still difficult to manufacture
– Complex device – needs correct carrier layers, anode/cathode
PETECThe Printable ElectronicsTechnology Centre
Large Area Coating Equipment (‘LACE’)
• 8” square panels
• 2 Slit die coaters: +/- 2% on 100-200nm, Aq and solvents
• Evaporator: metals and organics
• Encapsulation
• Robotic transfer throughout
• Capable of ~10 panels per 8hr day
PETECThe Printable ElectronicsTechnology Centre
LACE: Schematic
Double head slot die coater
Solvent coating module
Ambient coating module (aqueous)
Single head slot die coater
Evaporator (metal and organic) Encapsulation module
PETECThe Printable ElectronicsTechnology Centre
Organic Photovoltaics: Case Study
•7x energy needed to power the home falls on its roof, if only the energy could be harvested
•The European SRA predicts a 6% world market share (total market around $40bn) for Organic Solar Cells by 2023, with 45,000 resultant jobs and CO2 reduction of 13 million tonnes
•Petec helped Tata to research new polymer materials, develop a supply chain, and bring a product to market
United Kingdom CO2 Sources
PETECThe Printable ElectronicsTechnology Centre
Reasons
OPV can be made transparent, for applications in window glass
OPV can be flexible, and portable, for applications like this:
OPV can be printed much more cheaply in a roll
PETECThe Printable ElectronicsTechnology Centre
OPV Road Map Goals
• Improved encapsulation/sealing (WVTR 10-3 – 10-5 g/m2/d)
• (Barrier issue also impacts OLED, displays, etc)• Lifetime increased to 5, then 15 years• Efficiency towards 12% in long term• Reduced manufacturing costs through large area
R2R production technology• Move to more transparent materials
© Flisom
© UniSolar
PETECThe Printable ElectronicsTechnology Centre
What does this barrier WVTR number mean?
~100m
~50m
Imagine a polymer sheet the size of a football pitch: How much water would pass through this over a MONTH at various barrier performance levels?
PETECThe Printable ElectronicsTechnology Centre
What does this mean ?
100 10 1 1 X 1O-2 1 X 1O-4 1 X 1O-6
Raw Film Food Packaging Photovoltaics
OLEDDisplays
& Lighting
Solving the barrier issue described as a “brick wall” for the industry
PETECThe Printable ElectronicsTechnology Centre
Integrated Smart Systems (‘ISS’)• ISS covers the printing of any form of electronics using standard
printing processes that are well known to the print industry. • ISS products incorporate a mixture of devices such as sensors,
displays, lights, speakers, printed batteries & communication devices.
• These are currently manufactured using hybrid circuits – a mixture of silicon and printed electronics. Using these techniques, any printed item can become interactive. Potential applications for this technology are pretty much unlimited.
+
PETECThe Printable ElectronicsTechnology Centre
ISS: Coming Soon! Printing equipment to produce circuits Pick and place type methods of attaching components Inline/offline converting equipment for cut/crease/lamination
PETECThe Printable ElectronicsTechnology Centre
ISS: Applications
Duracell PowerCheck battery tester
PETECThe Printable ElectronicsTechnology Centre
Other areas of interest to ISS
• Electrochromic ink displays
• Printed Batteries
• Printed Memory
• Printed Sensors
• Printed RFID tags
PETECThe Printable ElectronicsTechnology Centre
How Big is the Opportunity?
PETECThe Printable ElectronicsTechnology Centre
How Big is the Opportunity?
• The global market for printed and potentially printed electronics is currently $2.2bn (IDTechEx)
but• Most are not printed and are on glass
substrates
PETECThe Printable ElectronicsTechnology Centre
How does this split?OLED Displays $1 Billion. Vacuum Processed on glass. Mainly Cellphones
Photovoltaics $360 million. Most are CIGS – vacuum processed on glass
Other inks: $420 million. RFID tag antennas, membrane circuits, bus bars etc.
Sensors: £130 million. Glucose test strips, ECG sensors, touch screens.
E-paper displays: £180 million
Inorganic AC Electroluminescent displays: $80 million.
Others: $30 million: Printed batteries, Logic , Memory, Electrochromic displays.
(Mostly)
Data © IDTechEx
PETECThe Printable ElectronicsTechnology Centre
What are the Projections?
Data © IDTechEx
PETECThe Printable ElectronicsTechnology Centre
ISS: An interesting opportunity
• Combines the established Print/Packaging Industry……..
• ……with the established packaged electronic components industry
• Market projections: global industry of $2.75bn in 2015 • Production of almost 400bn units by 2020. • It is likely that a significant proportion of these would
be ISS in nature.
PETECThe Printable ElectronicsTechnology Centre
Conclusion…….
………a growing industry that complements Si-based electronics and which has a number of entry points!
PETECThe Printable ElectronicsTechnology Centre
Manufacturing ChallengesHarvard Business Review, July-Aug 2009 on “Why Won’t the Kindle 2 be made in the USA?”
Electrophoretic display made in Taiwan
Flex connector made in China
Injection mould made in China
Wireless card made in S Korea
Controller board made in China
Li battery made in China
(Source Pisano and Shi 2009, “Restoring American Competitiveness”, Harvard Business Review, July-Aug 2009 p114-125)
Where can the U.K. and Europe gain value?
PETECThe Printable ElectronicsTechnology Centre
The Opportunity
• The UK and the EU have both released strategic agendas for research into printable electronics. Identified as an area with high potential growth for innovation, leading to sustainable revenue and job creation
• The reports conclude that Europe can succeed in key areas, winning FDI:– Original R&D and IPR for materials and
manufacturing, particularly OLED– Bulk materials manufacturing– Process equipment
• May be opportunities for manufacturing smaller screens – e.g. mobile devices
PETECThe Printable ElectronicsTechnology Centre
Challenges: High Volume Production
• Flexible substrates– Alignment– Distortion
• Still some vacuum steps!
• Batch vs. Continuous Production– Move to roll-to-roll (R2R)
processes
© PolyIC
PETECThe Printable ElectronicsTechnology Centre
Challenges: Materials
• Raw material costs– Economies of scale
• Durability– Application– Barrier Development– However, durability should be
matched to the requirementsof the application
PETECThe Printable ElectronicsTechnology Centre
Challenges: Stimulating market pull
• OEMs are very interested in the display and lighting potential of organic electronics.
• However, many companies are unaware of the potential benefits of the technology and so do not naturally ‘pull’ the technology: presently there is more of a technology ‘push’.
• Collaborative trans-national projects (e.g. FP7 CSA actions) are designed to unlock the full potential of the technology.
• In the UK, the Plastic Electronics Leadership Group supports and promotes the UK Plastic Electronics industry and seeks to stimulate market pull.
PETECThe Printable ElectronicsTechnology Centre
Challenges: Building the Supply Chain
Delivering printable electronics to market requires the bringing together of knowledge and organisations in a diverse range of fields…..
Materials Design
& Invent
Materials Scale UP
ComponentManufacture
Device Manufacture Integration
© Flisom © Solarcon© DTF
…..so how does PETEC help North Eastern companies?
PETECThe Printable ElectronicsTechnology Centre
PETEC
Consultancy Services
Joint Development Agreements
Access to State of the Art Equipment
Testing of materials and formulated products
PETEC is the National Centre for Printable Electronics. It helps organisationsto develop and industrialise products and services based on organic semiconductors and printed electronics
PETECThe Printable ElectronicsTechnology Centre
Where does PETEC operate?
TRL1 – Basic principles observed
TRL2 – Invention begins
TRL3 – Active R&D initiated
TRL4 – Basic components integrated
TRL5 – Improved integration, and test
TRL6 – Test in relevant environment
TRL7 – Prototype of operational system
TRL8 – Technology proven to work
TRL9 – Application operating in final form
UniversitiesInnovation Centres
Industry
PETECThe Printable ElectronicsTechnology Centre
Tool CapabilityPETEC has an extensive set of industry standard tools available to companies on an ‘open access’ model.
Visit http://www.uk-cpi.com/3_pages/focus/petec/ to follow a ‘virtual tour’ of the facility.
PETECThe Printable ElectronicsTechnology Centre
Networks
• PETEC is a core member of the PELG in the UK • It is a partner in two European projects (COLAE and Diginova)
which are specifically based on networks• It is a member of ‘PECOE’ (http://www.pecoe.org/) an
agreement between five Centres of Excellence in the UK to work together– CIKC – Imperial College Centre for Plastic Electronics – OMIC – PETEC – WCPC
• It is well connected to companies throughout the Plastics Electronics industry
PETECThe Printable ElectronicsTechnology Centre
Engagement
Sensors, printed
electronics onpackaging
PVSystems
SSLSystems
Displays
CO
NS
UM
ER
S
PETECPETEC
FilmSuppliers
MaterialsSuppliers
DeviceDesigners
Instrument& Tool
Vendors
AcademiaTrade
AssociationsConsultancyFunding
Bodies
Wilton R2R
Facility
SedgefieldScale-up & Prototype
Facility
Wilton Development
& Test Lab
OEMs
20052008 2008/9
From Innovation to Commercialisation
PETECThe Printable ElectronicsTechnology Centre
Customer Engagement
By You: Equipment HireCustomers’ staff are trained to operate the PETEC toolset and support the development. PETEC will train and supervise access and provide “on demand” consultancy advice to support the work content. Supplemented by incubator office accommodation.
For You: Contract ResearchPETEC’s trained staff operate the PETEC toolset and support the customers’ development. PETEC retains full control of access and operation of the kit
With You: Collaboration, Joint Venture PETEC’s staff work alongside 1 or more customer teams sharing resources and IP. Typically funded programmes (TSB, FP7)
PETECThe Printable ElectronicsTechnology Centre
Benefits to NE companies
• PETEC was set up with public funding
• Not only does it have international and national agendas, it is also focussed on helping SMEs in the North East region to engage with Printable Electronics
PETECThe Printable ElectronicsTechnology Centre
Benefits to NE Companies
• Members of the PETEC team can provide up to £1000 (equivalent) support to regional SMEs, providing they are below their de minimis limit.
• This can be taken as access to equipment, time with staff etc.
• Team members will work with companies to determine the best support that can be given
PETECThe Printable ElectronicsTechnology Centre
Benefits to NE Companies
• PETEC has already helped a number of regional SMEs to understand and engage with the Printable Electronics industry.
• Please make use of this National facility: you have unique regional access to it.
• Please contact us: we would be interested in discussing how we could help you!
PETECThe Printable ElectronicsTechnology Centre
Conclusions• Plastic Electronics is an exciting area with many
opportunities• It complements conventional electronics technologies• There are a number of challenges that need to be
met• PETEC is helping the industry to meet those
challenges and helping to ‘make it happen’• SMEs in the North East that are interested in
Printable Electronics could be supported directly by PETEC
http://www.youtube.com/watch?v=QqyW9vdS0x0&feature=related