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H2020

FLEXOLIGHTING Report Summary

Project ID: 644272
Funded under: H2020-EU.2.1.1.6.

Periodic Reporting for period 1 - FLEXOLIGHTING (FLEXOLIGHTING)

Reporting period: 2015-01-01 to 2016-06-30

Summary of the context and overall objectives of the project

Efficient, environmentally friendly and cost effective lighting is essential for daily life, but the replacements for the incandescent lamp that has been phased out are not ideal; the compact fluorescent lamp contains mercury and inorganic LEDs have poor colour rendering index (perception of colour) owing to the UV/blue emission from the LEDs.
FLEXOLIGHTING targets future full scale up of OLED lighting panels by developing a set of new materials, methods and processes to address the key issues of lifetime, light uniformity over large area and manufacturing on flexible or conformable surfaces that currently limit OLED technology being widely adopted.
The programme is designed to take key lab based and early development stage reel to reel capable printing technology currently outside the OLED production field and apply it to the OLEDs. It will leverage radical new developments in thin steel, plastic substrates and printing. The project will integrate low cost processes and tools, such as inkjet printers and organic vapour phase deposition systems and build a European wide supply chain. FLEXOLIGHTING utilises high performance materials from Merck and Brunel and uses them with low-cost production technologies for low-cost and high performance.
The project will include assessments of the impact of the FLEXOLIGHTING concept and a determination of the issues raised by adopting print technologies on end of life/disposal and recyclability. Detailed assessments of the design of a sustainable manufacturing network will also be addressed.

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 targets are summarised in below.

Area Target
High efficiency OLED lighting panels 100 lm/W (with external light extraction facilities, 40 lm/W without light extraction enhancements)
Life-time (t0.97) 1000 hours at 5000 cdm-2
Colour Rendering Index (CRI) Greater than 80%
Voltage Drop Less than 0.1 V
CIE Colour Coordinates (0.33±0.01), (0.33±0.01)
Cost per 100 lm €1

1. Warm white WOLEDs have been manufactured.
2. Feasibility of fabricating OLEDs on planarized steel and plastics has been demonstrated.
3. OVPD on Gen8.5 scale (2.2x2.5m) has been built and performance shown to be comparable to that of the traditional VTE method.
4. OVPD equipment for the production of conducting polymers has been built, commissioned and the production successfully validated.
5. OVPD equipment for the production of parylene planarization layer for metal oxide barrier coating has been constructed, commission and the process successfully validated.
6. Atmospheric (spatial) Atomic layer Deposition equipment commissioned and the process for producing metal oxide barrier layers successfully established and validated.
7. Flexoprinting of electrodes based on silver and copper inks have been successfully completed on industrial scale machine.
8. Inkjet printing of OLED materials demonstrated. Hybrid OLED devices have been successfully fabricated.
9. New hole injectors have been developed one of which is comparable to the world leading material.
10. Scale up of red, green and blue phosphorescent emitters (1x8g) have been completed as well as high triplet energy hosts and hole transporters.
11. A light extraction film was found to give up to 30% improvement in light output of WOLEDs.
12. ZnO inks prepared by Sol-Gel process found to be suitable for inverted OLEDs.

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)

1. Simple single stack warm OLED gives an efficiency of 20cd/A and 10lm/W.
Reduction in the cost of manufacture. Moving towards €1/100 lm. Acceleration in the deployment of solid state lighting. Colour tuning. Mirror like surface, providing design freedom. No UV light, so lower risk of skin or retinal cancer. Complies with the ROHS directive 2002/95/EC

2. Cool white OLED gives 40cd/A and 25lm/W (Interim Results).
Reduction in the cost of manufacture. Moving towards €1/100 lm.

3. Plastic and polymer planarised nickel coated steel shown to be suitable substrates for OLED.
Reduction in cost of 20% for the substrate by replacing the steel with glass and 80% reduction replacing the glass with plastic. Reduce dependence on glass. New products for the steel and plastic industry, safeguarding jobs.
Possible use as substrates for OPV (organic solar cells) and TFT.

4. OLEDs manufactured by OVPD have the same performance as VTE manufactured devices.
Reduction in cost of manufacture by 50% compared to VTE.
Reduction in OLED materials waste by 16%. Improvement in material utilisation from 5% (point source) to 20%.
European equipment manufacturers at the forefront of the OLED industry. Reduces CO2 and SO2 emissions.
Supports spirit of Directives 2012/27/EC, 2005/32/EC, 2002/91/EC, 2009/125/EC, 2002/95/EC.

5. Uniform films of OLED materials have been produced on Gen8.5 OVPD equipment for the first time in the world.
High uniformity on large panels (2.2x2.5m). Possible achievement of €1/100 lm.
Increases sales and safeguarding jobs.
Possible use for OPV and OTFT manufactured with small molecules.

6. Highly transparent (over 80% in the visible region) conducting polymer (100 Scm-1) has been produced by OVPD in world first.
Increased revenues. Europe in leadership position. Creation of new employment.

7 Continuous production of parylene film by OVPD.
Increased sales revenues. Put Europe in leadership position. Creation of new employment.

8 Production of metal oxide barrier film by PE-ALD potentially suitable for OLED encapsulation.
Increased revenues. Put Europe in leadership position. Creation of new employment.
Longer lifetime OLEDs.
New form factors. Also, impacting on OPV, OTFT, medicinal and food industries.

9. Production of metal oxide barrier layers demonstrated on a large area (400x500mm) by A-ALD for the first time.
Reduction in cost of manufacture of barrier films by 25%. Increased sales. Europe in leadership position. Creation of new employment. Longer lifetime OLEDs.
New form factors.
Impacting on OPV, OTFT, medicinal and food industries.

10. A new external light extraction film enhances light output by up to 34%.
Helps towards achieving €1/100 lm. Europe in leadership position. Creation of new employment.
Longer lifetime OLEDs. New flexible form factors for lighting fixtures.

11. Large area (100x100mm) OLEDs demonstrated.
Helps towards achieving €1/100 lm. Put Europe in leadership position. Creation of new employment.
Longer life-time OLEDs. New flexible form factors for lighting fixtures.
European equipment manufacturers at the forefront of the OLED industry. Contributes to corporate and social responsibility by reducing the CO2 and SO2 emissions.
Complies with EU Directives 2012/27/EC, 2005/32/EC, 2002/91/EC, 2009/125/EC, 2002/95/EC.

12. A new patentable hole injector invented.
Reduction in the cost. Licensable products. Increased revenues.

13. Inkjet printed PEDOT for OLEDs demonstrated.
Reduction in the cost of manufacture by 60% compared to VTE. Reduction in waste. Lower capital costs.
Helps towards achieving €1/100 lm. Put Europe in leadership position. Creation of new employment.
New flexible form factors for lighting fixtures.
Put European equipment manufacturers at the forefront of OLED industry. Contributes to corporate and social responsibility by reducing CO2 and SO2 emissions.
Complies with EU Directives 2012/27/EC, 2005/32/EC, 2002/91/EC, 2009/125/EC, 2002/95/EC.

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