Printing based Manufacturing and Integrationof Flexible Electronic Systems

Harri Kopola, Prof., VP Strategic ResearchVTT Technical Research Centre of FinlandHarri.Kopola@vtt.fi ,Tel.: +358405574867

Content

VTT Printed Intelligence 2012 | For external use

Printed and Flexible Electronics concept cases and applicationsPrinted and Flexible Electronics concept cases and applications

Hybrid In-mould IntelligenceHybrid In-mould Intelligence

Roll-to Roll Manufacturing and Hybrid IntegrationRoll-to Roll Manufacturing and Hybrid Integration

VTT and VTT Printed Intelligence

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PrintoCent for industrialisation and commercialisationPrintoCent for industrialisation and commercialisation

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SummarySummary66

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VTT Technical Research Centre of Finland

VTT ISa globally networked multi-technological applied research organisation

VTT HASextensive cross-disciplinary technological and business expertise unique research infrastructurecomprehensive global partnership networks in business, industrial and research communities

VTT CREATESnew technology and science-based innovations in co-operation with domestic and foreign partners

Turnover 316 M€ (2012) • Personnel 3,206 (31.12.2012)

VTT Center for Printed Intelligence in brief

Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging

Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps

Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging

Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps

Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing

Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing

Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization

2010-- Pilot Factory 2012

R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration

Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization

2010-- Pilot Factory 2012

R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration

VTT Printed Intelligence 2012 | For external use

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.

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

R2R deposition of functional materials

Pilot Factory for Printed Intelligence at VTT

R2R testing of functional layers

R2R injection moulding over printed structureR2R assembly of components

Example:

Deposition of 4 layers in register with wanteddeposition processup to 2 160m2 / day

Example:

Assembly of printedand Si-componentsfrom 300µm to 60mm sizeup to 100 000pcs / day

Example:

Injection moulding with selected plastic materialover printed layer with assembled components5 000pcs/day

Laboratory facilities to fine tune the inks, printing procesess and make proof of concept demonstrators

R2R processed Printed Intelligence product

VIDEO KONEISTASection from video:2:26-2:259

Example:

Testing of connectionsshort cuts and resistivitybetween points50 000 measures /day

Current R2R process capability

Pilot Factory for Printed Intelligence at VTT

Material possibilities

Available R2R processes:

- Forward gravure- Reverse Gravure- Flexo printing- Rotary Screen- Slot die coating- Hot embossing- Lamination- Diecutting

Drying methods:

- Hot air ovens- UV- IR

Multilayer processing:

- Up to 4 layersdeposited at one run

- +/-50µm accuracy in both direction

Process speeds:

- Speed range from0,1 to 30 m/min

- Gravure and hotembossing up to 120 m/min

Dimensions:

- 300mm wide web- 409,575mm repeat

length

Printing capability:- 100µm conductive

lines with 100µm gaps

- ITO patterning

Substrates used:- Around 100 different

substrates tested- Plastics from 36µm

to 500µm (OPP, PET, PEN, PMMA, CA etc.)

- Papers without and with coating

- Metal foils

Inks used:- Conductive inks- Isolative inks- Semiconductor inks- Commercial inks- Proprietary inks- Emitter inks- Light abosorbing

inks- Etc. A long list

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Concepts for Integration

• Printed, organic and flexible electronics

• Roll-to-roll manufacturing technologies for electronics, optics and sensors

• Integration to devices, systems and products

VTT creating functional products

from roll-to-roll printingR2R processed OPV foil Solar energy module Autonomous Energy Source

R2R processsed OLED foil 7-segment OLED display In-moulded OLED element

R2R printed memory Printed memory (WORM) Data-carrying card

R2R hot embossing Microfluidic channels Opto-fluidic sensor with light source

R2R Printed sensors Wide area sensor matrix Touch control for signage& passives

Business Forecasts

Freedom of Design

Organic Photovoltaicfor energy harvesting

Organic Light Emitting Diodesin product package

Microfluidic channels

Any shape for light emitting surfaces, solar cells, touch sensors, microfluidic channels etc. with printing

• Arbitrary shapes, any size, decorative design

• Flexible, thin and light-weight

• Various colours, transparency

• Scalability, customising

Printed & Flexible Electronics OpportunitiesBuildings

Key features:Easy integrationInvisible - DecorativeDistributed in large-area

Asset management with autonomous sensors in large-area surfaces:• Temperature, humidity, air flow &quality etc. Printed,

and/or Si, OFT switching• Arbitrary shape and decorative energy

harvesting &storage with printing • Zero-power electronics, wireless power

Energy efficiency and Comfort with Smart lighting:• Thin, conformal, large-area illuminated surfaces• Integrated smart control, wireless communication

and interoperability e.g. with 3D depth sensors• Hidden configurable user interfaces and control

panels is walls, furniture

Smart windows and active facades:• Controllable transmission windows with

electrochromic films• Transparent User Interfaces• Building integrated Photo Voltaic

Turn any surface to smart User Interface

Capacitive sensors –touchless

Resistive sensors –TransparencyCourtesy FP7 FLEXIBILITY

Force sensors –robustness

Wallpapers, construction elements or furniture canbecome User Interfaces

• Proximity sensing for wide-area user interfaces

• Hidden/visible UI elements for every surface -also conformal

• Thin modular structure for quick installation and configuration

• IoT compatibility – App and cloud connected

Printed & Flexible Electronics OpportunitiesAutomotive

Key features:Reduced weight, volume and cablingIncreased safety and comfortFuel savings and reduced emissions

Conformal In-mould Interiors:• Integrated lighting & overhead consoles• Control panels for doors, armrests, pillars and

central console• Printed Heaters for floors, seats

Conformal autonomous exteriors:• Photovoltaic and batteries • Tail lights• Embedded climatic sensors

Vision enhancement & info availability:• Transparent displays • Head-up-display optical films• Sun protection electrochromic films

Courtesy Fiat

Printed & Flexible Electronics OpportunitiesPersonal Wellbeing

Key features:Disposable Easy to useLow cost

Wellbeing:• Detect volatiles in breath or food with printed

sensors• Detect volatiles or bacteria in food • Disposable indicators for water quality

Cosmetics:• Flexible solution for electrical and light-based

skin care with disposable batteries, LEDs• Microfluidic solutions for liquid and fragrance

delivery

Health:• Printed medical diagnostics based on

microfluidistics• Flexible hybrid disposable healthcare sensors

with printable components such as sensors, displays and batteries.

New flexible products- case Disposable healthcare sensor

Single-patient use disposable healthcare sensor

• Concept demonstrated

• Simple flexible structure with polycarbonate foil, printed wirings, SMD components bonded with conductive adhesive

• Connector over-moulded on the functional foil: mechanical locking, electrical connections and plastic embedded SMD components.

Over-moulded connectorHealthcare sensor

Developed in TEKES funded project Mobisens for GE Healthcare

Printed & Flexible Electronics OpportunitiesConsumer Electronics & Accessories & Games

Key features:Design FreedomConformal functional surfacesReduced complexity and volume

Design Freedom :• Arbitrary shape and decorative battery life

extension with printed photo voltaic• Elimination of holes and interconnects with

printed touch controls• Thin, flexible, light-weight and robust for

wearable electronics with elastomer over-moulding

Integrated signage and lighting:• Conformal indicators and back-lighting with

ultra-small ILED and OLEDs• Secondary displays with ILEDs,

electrochromics and electrophoretic displays

New user experience:• Control by bending • Touch controls• Combining with graphical products

Printed & Flexible Electronics OpportunitiesRetail

Key features:Eye-catchingInteractiveProductivity

Point-of-purchase:• Attention and information• User interface connecting physical and digital

world for new WEB services• Interaction and cloud connection with NFC

smart phone

Interactive brand advertising:• Blinking lights with ILEDs and OLEDs +

wireless power• Changing images with active paper or

electrochromic displays• Electronic shelf labels

Logistics:• Logistic chain condition monitoring with printed

sensors, displays, memory, battery• Active 2D&3D RFID tags for goods &

container tracking & history• Stock management with force sensors

Flexible Signage and lighting

Flexible OLEDs LED chips on flex Hidden indicator lights

Indicators and backlighting elements to be integrated to thin, flexible and conformal end products

• Interactive packaging and point-of-sale products

• Gaming and entertainment applications

• Interactive graphical products such as posters with user interfaces

• Smart cards and smart labels

• Consumer electronics and interior design products

Hybrid in-mould intelligence

Integrated functionalities:Sensors & Sensor arrays • User feedback • Processing & Communication •

Power supplies & Storage • Antennas & Wiring

Integration of printed and surface mount discrete electronics components into freeform intelligent products

using roll-to-roll compatible mass manufacturing methods.

Next generation In-Mould-Labelling

from graphic overlays, front panels and labels

owardsmore integrated

Assembled Film Over Moulding

Assembled Film Over-moulding-Optics-electronics-mechanics combined

Smart covers In-moulded OLED Plastic optics

Next generation In-Mould-Labelling from graphic overlays, front panels and labels towards more integrated Assembled Film Over Moulding

• Flexible OLED foil embedded into 3-D mechanical structure

• LED bare dies/packages + light guiding optics• Capacitive touch controls, wirings, control

electronics etc.• Integrated battery compartment and on/off switch

can be formed in the injection moulding process without any additional post-processes

New Product concepts: Spin-offs

Commercialization case of hybrid In-mould Intelligence

• Company founded 2011• Cost-effective touch panels• Highly integrated, non-breakable structure• Tablet, phone and PC markets• Patented optical touch screen technology • www.tactotek.com

Increase the maturity level

Copyright VTT

Printed Intelligence Industrialisation - PrintocentCentre for business development in the area of Printed

Intelligence and Optical Measurement.

Offers a world-class Roll-to-Roll pilot manufacturing environment based on Printed Intelligence processes.

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

New Printocent Industry Cluster: Eco-system building

Now 35 companies committed

Contact Director Ilkka Kaisto (ilkka.kaisto@vtt.fi)

Copyright VTT

GoodWillerOy

Micro & startup SME LSE

PrintoCent Industry Cluster members 31.8.2013

Copyright VTT

PrintoCent 2013 – 2015Cluster and the Three programmes

COLAE- pan-European supply chain in Organic and Large Area Electronics

COLAE project connects players within the industry to create and develop a pan-European supply chain that deliver tangible value and benefits for its members.

COLAE Services:Enhancing awareness OLAE trainingFeasibility networkVirtual OLAE foundry

More Info: www.colae.euAcronym: COLAEStarting date: 1 Sep 2011Duration: 36 monthsCall: FP7-ICT-2011-7EC budget: EUR 3.75MCoordinator: VTT Technical Research Centre of Finland

Summary

• Printed Intelligence and Electronics Technology and Components demonstrated

• Roll-to-Roll and Hybrid Integration Pilot Factory available• Time for System and Product development• We wellcome new Cooperation Partners to join our research and

commercialization effortscreating application driven value chainsmembership in PrintoCent Ecosystemor bilateral co-operation

Wireless power Hybrid integration Printed conductors Embedded Electronics Embedded Software

VTT creates business from technology

Contact information:Harri Kopola

Prof., VP Strategic ResearchHarri.Kopola@vtt.fi

Tel.: +358405574867

PRINSE’14 – Printed IntelligenceIndustrial SeminarIn Oulu, Feb. 25-26, 2014