Production methods for large area printed electronics and organic photovoltaics. Thomas Kolbusch, Vice President
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1 Production methods for large area printed electronics and organic photovoltaics Thomas Kolbusch, Vice President COATEMA Coating Machinery GmbH 1
2 Large area printed electronics Summary Introduction Coatema What does printed electronics mean Overview on OPV Scaling up new technologies Technologies & processes Summary COATEMA Coating Machinery GmbH 2
3 Upscaling from Lab2Fab Overview Coatema COATEMA Coating Machinery GmbH 3
4 Introduction Coatema The one stop shop solution Batch type operation R2R on small scale Semi production on small scale Custom made small scale Pilot production Standard layouts Bespoken euqipment on big scale Fab system inline COATEMA Coating Machinery GmbH 4
5 Introduction Coatema Innovation through times COATEMA Coating Machinery GmbH 5
6 Upscaling from Lab2Fab What does printed electronics mean? COATEMA Coating Machinery GmbH 6
7 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 with low thickness tolerance and high uniformity OTFT: High lateral resolution, small feature size and high density integration COATEMA Coating Machinery GmbH 7
8 What does printed electronics mean? The future market It will be integrated devices: Facess FP7 project finished in 2011 thin film battery, polymer solar cells, bus bar integrated chip, sensor or ZigBee radio We will see the development of a new industry value chain in Europe Local custom made production on demand versus big scale! COATEMA Coating Machinery GmbH 8
9 What does printed electronics mean? The future market COATEMA Coating Machinery GmbH 9
10 What does printed electronics mean? The Roadmap 2011 Picture sources: Konarka, Schott Solar COATEMA Coating Machinery GmbH 10
11 Upscaling from Lab2Fab Scaling up new technologies COATEMA Coating Machinery GmbH 11
12 Product development Scaling up technologies COATEMA Coating Machinery GmbH 12
13 Equipment development The Easycoater COATEMA Coating Machinery GmbH 13
14 Equipment development The Smartcoater COATEMA Coating Machinery GmbH 14
15 Equipment development R2R in nitrogen enviroment COATEMA Coating Machinery GmbH 15
16 Equipment development The Click&Coat COATEMA Coating Machinery GmbH 16
17 Equipment development Semi - Production lines COATEMA Coating Machinery GmbH 17
18 Equipment development Production lines COATEMA Coating Machinery GmbH 18
19 Equipment development 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! COATEMA Coating Machinery GmbH 19
20 Upscaling from Lab2Fab Overview on organic photovoltaics COATEMA Coating Machinery GmbH 20
21 Processes Process Layout for OPV The common feature is that these solar cells can can be printed or being coated: CIGS cupper indium gallium selenide DSSC dye sensitized solar cells Small Molecules Polymer solar cells COATEMA Coating Machinery GmbH 21
22 Processes Efficiency reached today NREL COATEMA Coating Machinery GmbH 22
23 Processes Production chain for modules It is not only printing or coating to reach efficiency record modules! COATEMA Coating Machinery GmbH 23
24 Upscaling from Lab2Fab Technologies & Processes COATEMA Coating Machinery GmbH 24
25 Technologies & Processes Overview and Basics The production of flexible printed electronic devices is a bundle of different existing and non existing R2R production technologies which are integrated inline like: Surface treatment Printing Coating Photolithography Nanoimprinting Laser patterning Soldering Pick & place COATEMA Coating Machinery GmbH 25
26 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 COATEMA Coating Machinery GmbH 26
27 Processes 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 COATEMA Coating Machinery GmbH 27
28 Technologies Printing Systems COATEMA Coating Machinery GmbH 28
29 Technologies Printing Parameters COATEMA Coating Machinery GmbH 29
30 Technologies Printing Parameters Printing method Printing Nip Ink Layer Feature Regis- speed pressure viscosity thickness size tration (m/s) (MPa) (Pa s) (µm) (µm) (µm) Flexography ,1-0,5 0,01-0,5 0, Gravure ,5-5 0,01-0,2 0, >10 Offset , , >10 Screen printing 2-0, >25 Inkjet ,001-0,03 0,01-0,5, 20 (UV) < COATEMA Coating Machinery GmbH 30
31 Technologies Printing Systems Screen printing Flexo printing Gravure printing COATEMA Coating Machinery GmbH 31
32 Technologies Printing Systems Gravure Printing Parameters: Printing Speed (m/s) Nip Pressure (MPa) 1,5-5 Ink viscosity (Pa s) 0,01-0,2 Layer Thickness 0,04-12 µm Feature Size µm Resolution µm COATEMA Coating Machinery GmbH 32
33 Technologies Printing Systems Gravure/ Reverse Gravure Printing COATEMA Coating Machinery GmbH 33
34 Technologies Printing Systems Flexo Printing Parameters: Printing Speed (m/s) 3-10 Nip Pressure (MPa) 0,1-0,5 Ink viscosity (Pa s) 0,01-0,5 Layer Thickness 0,1-12 µm Feature Size µm Resolution µm COATEMA Coating Machinery GmbH 34
35 Technologies Printing Systems Flexo Printing COATEMA Coating Machinery GmbH 35
36 Technologies Printing Systems Screen Printing Parameters: Printing Speed (m/s) 2 Nip Pressure (MPa) Ink viscosity (Pa s) 0,1-50 Layer Thickness µm Feature Size Resolution 10-50µ COATEMA Coating Machinery GmbH 36
37 Technologies Printing Systems Screen Printing COATEMA Coating Machinery GmbH 37
38 Processes Registration control system COATEMA Coating Machinery GmbH 38
39 Technologies From Lab2Fab COATEMA Coating Machinery GmbH 39
40 Technologies Scribing/Patterning Systems COATEMA Coating Machinery GmbH 40
41 Technologies Laser Patterning System Laser Parameters: Scribing speed (m/min) 2-10 Structure width µm patented beam delivery for maximum precision and flexibility integration of cw, ns, ps-laser sources depending on application scribing process by beam splitting from 1 to 10 parallel beams integration of galvo-scanheads possible full area processing of foil in / across transport direction by CNC code COATEMA Coating Machinery GmbH 41
42 Technologies Laser Scribing System Height profile. 40µm wide scribe (smaller or wider scribe is possible!!). The build up at the scribe edge is less than 15nm. Virtually no burr/melting COATEMA Coating Machinery GmbH 42
43 P 1 P 2 P 4 P 3 Edge Delete Technologies Laser Patterning System Top contact TCO Absorber 1 Back contact Barrierer Substrat Metall, Polymer COATEMA Coating Machinery GmbH 43
44 Technologies Nanoimprinting System Nanoimprinting Parameters: Printing Speed (m/min) 0,1-20 Nip Pressure (MPa) Ink viscosity (Pa s) Layer Thickness Feature Size Resolution COATEMA Coating Machinery GmbH 44
45 Technologies Nanoimprinting System COATEMA Coating Machinery GmbH 45
46 Technologies Nanoimprinting System COATEMA Coating Machinery GmbH 46
47 Technologies Nanoimprinting System COATEMA Coating Machinery GmbH 47
48 Technologies Hot embossing System Hot embossing Parameters: Printing Speed (m/min) 0,1-30 Nip Pressure (MPa) Register controlled COATEMA Coating Machinery GmbH 48
49 Technologies Hot embossing System COATEMA Coating Machinery GmbH 49
50 Technologies Photolithographic System COATEMA Coating Machinery GmbH 50
51 Technologies Photolithographic System COATEMA Coating Machinery GmbH 51
52 Technologies Photolithographic System COATEMA Coating Machinery GmbH 52
53 Technologies Photolithographic System COATEMA Coating Machinery GmbH 53
54 Technologies Coating Systems COATEMA Coating Machinery GmbH 54
55 Technologies Coating Systems Knife System Double Side System Commabar System Case Knife System Engraved Roller 2 Roller System 3 Roller Combi System Micro Roller System 5 Roller System Reverse Roll System Rotary Screen System Dipping System Slot Die System Curtain Coating System Reverse roll coater Hotmelt Slot Die System Powder Scattering System COATEMA Coating Machinery GmbH 55
56 Technologies Coating Systems Coating Chemistry Coating Processes Process control Drying Rheology Viscosity Viscoleasticity Type of solvents Amount of solids Van der Waals force Sheer ratio Adhesion/Cohesion Coating systems Single or Multilayer coatings Direct coatings Transfer (indirect) coatings Substrate speed Layer Thickness Coating accuracy Process layout Tension control system Material guiding system Inline parameter control Quality control Convection drying Contact drying Infrared drying Sintering NIR High Frequency UV crosslinking systems Substrate Pretreatment Environment Finishing Surface tension Dimension stability Surface structure Contact angle Corona Plasma Cleaning Humidity Temperature Inert Conditions Calendaring Embossing Slitting COATEMA Coating Machinery GmbH 56
57 Technologies Printing Coating Systems Slot Die Coating COATEMA Coating Machinery GmbH 57
58 Upscaling from Lab2Fab From Lab2Fab or vice versa COATEMA Coating Machinery GmbH 58
59 Technologies 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? COATEMA Coating Machinery GmbH 59
60 Technologies From Lab2Fab COATEMA Coating Machinery GmbH 60
61 Technologies Going to Fab COATEMA Coating Machinery GmbH 61
62 Technologies Going to Fab COATEMA Coating Machinery GmbH 62
63 Technologies Going to Fab COATEMA Coating Machinery GmbH 63
64 Technologies Going to Fab COATEMA Coating Machinery GmbH 64
65 Technologies Going to Fab COATEMA Coating Machinery GmbH 65
66 Summary Production facility for BIPV COATEMA Coating Machinery GmbH 66
67 Upscaling from Lab2Fab Summary COATEMA Coating Machinery GmbH 67
68 Processes Summary 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 COATEMA Coating Machinery GmbH 68
69 COATEMA Coating Machinery GmbH Roseller Str. 4 D Dormagen / tkolbusch@coatema.de COATEMA Coating Machinery GmbH 69
70 COATEMA Coating Machinery GmbH 70
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