Community Research and Development Information Service - CORDIS

H2020

ROLL-OUT Report Summary

Project ID: 644631
Funded under: H2020-EU.2.1.1.1.

Periodic Reporting for period 1 - ROLL-OUT (High-performance, Flexible, AUTOnomous Systems manufactured with Unique, Industrial ROLL-to-roll equipments)

Reporting period: 2015-01-01 to 2015-12-31

Summary of the context and overall objectives of the project

The goal of the ROLL-OUT project is to create a multi-purpose technology for, thin, large-area, high-performance, smart, and autonomous systems comprising integrated circuits, sensors, and electronics, advancing the packaging, automotive interiors and textile industries beyond their traditional scope. The key features are high-performance circuits and components. To fabricate high-performance circuits, the project intends to use novel, hybrid, moderate-temperature, roll-to-roll processes, namely sputtering, Atomic Layer Deposition (ALD) and screen-printing on thin, flexible, large-area substrates. This will enable enormous value addition to the products of European industries without adding any significant extra cost. Participation of industrial partners from the multiple business areas [ILAB (consumer product packaging), Maier (automotive components and systems) and FoV (smart textiles)] justify the relevance and impact of the ROLL-OUT project.
There are a set of scientific and industrial objectives of the project:

Scientific objectives:
1. In-free oxide transistors fabricated on flexible substrates using sputtering and ALD processes, exhibiting mobility above 20 cm2/Vs with excellent stability under light and negative gate bias stress (ΔVT<0.5 V after 1h stress).
2. R2R printed integrated circuit with operational amplifier and differential amplifier based on In-free semiconductor oxide transistors. Adaption/modification of process parameters to meet the performance of the reference devices processed by non-R2R sputtering and ALD.
3. Pressure sensors printed in a R2R process that can detect changes in the ranges 0.05–20 kg/cm2 with more than 10 million actuations after integration into smart autonomous systems.
4. Si temperature sensors processed by printing techniques in ambient air environment.
5. Printed, solid-state batteries with capacity of 150 mAh/gm (active material) and cell-voltage of 2 V.

Industrial and exploitation objectives:
6. Development of Sputtering and Atomic Layer Deposition into a R2R system for application in large-area electronics manufacturing. Demonstration on substrate sizes with a web width up to 7-10 cm and length up to 90 m will be carried out for this purpose.
7. A R2R-fabricated, flexible autonomous system with integrated circuits, sensors and power source.
8. A door-handle demonstrator for automotive applications will be fabricated with the proposed TOLAE technology until the end of the project. Typically used switches for control of the window opening/closure will be replaced by a pressure sensor array including sensor evaluation and communication with the board electronics. Integration into the harsh product manufacturing cycle and validation by automotive standards will show the feasibility.
9. Large area distributed pressure sensors will be integrated between different layers of car seat textiles for measuring occupancy and weight of the passenger. TOLAE electronics will allow for a reduction of the wiring and assembly effort.
10. An autonomous (i.e. battery driven) multi-sensor application will be developed for beverage packaging independently indicating:
a. a loss of under-pressure upon unintended or intended breaking of the sealing (pressure sensors)
b. the fill level of opaque bottles (capacitive sensors)
c. The temperature of the drink to support the user decision for or against consumption.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The ROLL-OUT project has completed 1 year on 31.12.2015. During the first year the project work has progressed as planned. The activities of the project have already been reported in form of 11 technical and management deliverables. The technical work is also summarized in the Periodic Report – Part B document. Simultaneous work has been carried out to develop sputtered and solution-processed, low-temperature metal-oxide transistors, designing of basic electronic circuits based on the transistors, development of Roll-to-Roll equipment for unique processes like Atomic Layer Deposition and Sputtering, fine-tuning of components like pressure and temperature sensors and batteries and design and development of prototypes for application of the circuits and components in door-handle and packaging applications. Several collaborative scientific missions have been undertaken during this period.

The most significant results from the project so far have been:

1. Definition of circuit building blocks and specification of the circuits to be implemented in the project has been identified.

2. Sputtered and patterned In-free oxide semiconductor films for transistors have been demonstrated and are the basic building block for the circuits to be implemented in the project.

3. Roll-to-Roll Sputtering and Atomic Layer Deposition is developed and is operational for building the circuits within the project.

4. Application of the electronic building blocks and other components (sensors, batteries, etc) into specific commercial application - in car-door handles and beverage bottles, has been identified and development of prototype has started.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The first six-months of the Roll-Out project have been primarily spent on defining the circuit specifications and identifying the specific applications of these circuits in industrial cases. These activities were initiated on the basis of existing state-of-the-art (SOTA) and the outcome of the planning, as reported in the deliverables, are beyond the existing SOTA.

Technical development has also been carried out in the form of development of low-temperature, printed metal-oxide transistors on flexible substrates. This work was well beyond the SOTA and was acknowledged as a publication in the journal Advanced Materials. Work on low-temperature sputtered transistors with In-free material – Zinc Tin Oxide was also conducted in the project and will be reported soon in a high-impact journal. This proves the significance of this research beyond the existing SOTA.

The development of unique Roll-to-Roll Sputtering and Atomic Layer Deposition equipment by industrial partners within the project is another activity beyond SOTA. This will have a significant commercial impact globally in terms of advanced industrial equipments.
The development of the circuits and the autonomous systems in Roll-Out is envisioned to have significant commercial impact. This is underlined in the commercial roadmap produced within the project and reported as a deliverable. Socially, this will lead to the creation of internet-of-things with smart everyday objects in automotive and packaging.

Related information

Record Number: 186667 / Last updated on: 2016-07-14