Final Report Summary - FLEXONICS (Ultra-high barrier films for r2r encapsulation of flexible electronics)
The 'Ultra-high barrier films for r2r encapsulation of flexible electronics' (FLEXONICS) research activities performed to developed the required and missing material systems, processes and their process control for the production of transparent flexible encapsulation materials for the new generation of FEDs, with emphasis to the ultra-barrier films, and will link the traditional roll-to-roll (r2r) polymer film conversion industry and current optoelectronics industry. The main objectives of FLEXONICS were the following:
1) To develop novel ultra barrier material systems in multilayer form (with individual layer thicknesses of a few nm), consisting of preferably not more than two pairs of alternating layers from inorganic materials and inorganic-organic hybrid polymers. In addition, the layer systems have to be highly optically transparent in the visible spectral range for OLEDs and in the NIR - UV range for organic photovoltaics (OPVs).
2) To establish physical and chemical processes suitable for the deposition of ultra high barrier layer systems, via plasma assisted PVD and CVD processes, for the fabrication of inorganic barrier layers and via atmospheric pressure liquid phase coating and cross-linking processes, for hybrid polymeric interlayers, and to adapt the appropriate r2r processes (with process speeds up to 5 m/sec) for large scale production. In order to achieve the required properties of the multi-layer system, the properties of each individual layer have to be monitored and controlled in-line.
3) To develop new optical sensing techniques with sub-nm resolution to probe organic / inorganic layer and interfaces, and product functionality in msec time, and to integrate them into r2r processes in order to guarantee maximum uniformity in the intermediate and final product properties.
Impact of the project
FLEXONICS deals with the development of a new generation of flexible, transparent, ultra-barrier layers and the adaptation of the production process for the encapsulation of flexible opto-electronic devices (FEDs) with high precision, quality and uniformity, through intelligent optical monitoring and process quality control.
FLEXONICS research activities were performed to develop the process step that is missing, essential for the development and reliability of FEDs (OLED-based displays and OPV modules), that is their encapsulation into a transparent polymer medium, in order to protect FEDs against atmospheric oxygen and water-moisture which are harmful for their performance and long-term stability.
The science and technology prospects of the research that were performed in FLEXONICS in the above fields are all focused to achieve ultra high barrier properties on polymer films that will lead to a new generation of radically innovative products, for industrial use and for consumer applications. FEDs will be used for communication and visualising of information, and generating electricity through renewable sources (based on OLEDs and OPVS modules, respectively) and will have a major impact on our daily life. The above generated knowledge of FLEXONICS, in order to be used for further research and development and to reach other production applications was and will continue to be disseminated according to a specific policy and plans.
FLEXONICS serves one of the most rapidly growing sectors in today's industry. Related manufacturers of materials, process and monitoring equipment for different industries (displays, solar energy devices) and their suppliers (mainly SMEs) are presently covering about one million of direct working places. The high level of sophistication in material systems, production processes and equipment will generate several tens of thousands of highly specialised, knowledge intense workplaces. Synergies will be achieved and sustained from lab scale up to all stages of the production chain and from RTD to commercialisation. This will have a major impact on EU competitiveness since it will benefit society through knowledge integration in a new multidisciplinary area, by promoting knowledge and learning capabilities due to requirement for the implementation and dissemination to potential user groups. The environmental EU policy is addressed by the increased use of new types of higher efficiency lightweight OPVs requiring less input of resources, and by reduced waste (around 50 %) of r2r production processes. Finally, the controlled production lines and improved visualisation of information will potentially improve the EU citizens quality of life.
The market of optoelectronic and electronic devices is one of the most rapidly growing sectors in today's industry. The production technology for OLED displays on flexible polymer substrates through r2r technology will expand this already flourishing market towards a series of new applications. PV devices are another fast-growing sector of optoelectronic industry. Again, the introduction of flexible PVs produced by r2r technology on polymer substrates will substantially expand the market far beyond the figures foreseen for rigid PVs.
The deployment of in-line process control on r2r machines results both in the improvement of product properties and higher process stability and in reduction of production costs by minimising and avoiding rejects, as well as in lower costs for exploitation, maintenance and quality control. Therefore, the whole strategy behind FLEXONICS represents the transition from resource intense industries (using e.g. glass, thick plastic parts, metal) towards knowledge-based industries (e.g. by incorporating intelligent and controllable processes that deliver materials with high functionality). Finally, the new optical monitoring units and platforms will also be available for other industrial sectors, such as semiconductors, biochips etc. These developments will drive sales in specialised machine systems, by a factor of some tens above the sales for the optical equipment alone, due to their enhanced performance and thus will boost the market share of European manufacturers of r2r film conversion equipment. Such a trend will strengthen the competitiveness of the participating companies and especially their customers (mainly SMEs) on an international level, maintain technical and economical leadership and improve employment across Europe.
FLEXONICS contributes to the standardisation by defining typical figures of merit, for example:
- in efficiency and power generation for solar cell test-devices. The development of new fabrication methods will have a positive impact on quality standards and environmental norms for industrial production.
- new standards in the measurement limits, modelling and analysis methodology established.
- expand the current limits for water vapour transmission and establish new standards in the measurement resolution.
- new methodology for the offline measurement of oxygen and water vapour at low permeation that is based on a photochemical sensing system.
Website
The FLEXONICS website has been created to act as a permanent dissemination channel, updated with reports on progress and results emerging from FLEXONICS. It also provides a mechanism for interested parties to contact the appropriate FLEXONICS partners in order to find out more about the project or its results. The website is: http://www.flexonics.org
1) To develop novel ultra barrier material systems in multilayer form (with individual layer thicknesses of a few nm), consisting of preferably not more than two pairs of alternating layers from inorganic materials and inorganic-organic hybrid polymers. In addition, the layer systems have to be highly optically transparent in the visible spectral range for OLEDs and in the NIR - UV range for organic photovoltaics (OPVs).
2) To establish physical and chemical processes suitable for the deposition of ultra high barrier layer systems, via plasma assisted PVD and CVD processes, for the fabrication of inorganic barrier layers and via atmospheric pressure liquid phase coating and cross-linking processes, for hybrid polymeric interlayers, and to adapt the appropriate r2r processes (with process speeds up to 5 m/sec) for large scale production. In order to achieve the required properties of the multi-layer system, the properties of each individual layer have to be monitored and controlled in-line.
3) To develop new optical sensing techniques with sub-nm resolution to probe organic / inorganic layer and interfaces, and product functionality in msec time, and to integrate them into r2r processes in order to guarantee maximum uniformity in the intermediate and final product properties.
Impact of the project
FLEXONICS deals with the development of a new generation of flexible, transparent, ultra-barrier layers and the adaptation of the production process for the encapsulation of flexible opto-electronic devices (FEDs) with high precision, quality and uniformity, through intelligent optical monitoring and process quality control.
FLEXONICS research activities were performed to develop the process step that is missing, essential for the development and reliability of FEDs (OLED-based displays and OPV modules), that is their encapsulation into a transparent polymer medium, in order to protect FEDs against atmospheric oxygen and water-moisture which are harmful for their performance and long-term stability.
The science and technology prospects of the research that were performed in FLEXONICS in the above fields are all focused to achieve ultra high barrier properties on polymer films that will lead to a new generation of radically innovative products, for industrial use and for consumer applications. FEDs will be used for communication and visualising of information, and generating electricity through renewable sources (based on OLEDs and OPVS modules, respectively) and will have a major impact on our daily life. The above generated knowledge of FLEXONICS, in order to be used for further research and development and to reach other production applications was and will continue to be disseminated according to a specific policy and plans.
FLEXONICS serves one of the most rapidly growing sectors in today's industry. Related manufacturers of materials, process and monitoring equipment for different industries (displays, solar energy devices) and their suppliers (mainly SMEs) are presently covering about one million of direct working places. The high level of sophistication in material systems, production processes and equipment will generate several tens of thousands of highly specialised, knowledge intense workplaces. Synergies will be achieved and sustained from lab scale up to all stages of the production chain and from RTD to commercialisation. This will have a major impact on EU competitiveness since it will benefit society through knowledge integration in a new multidisciplinary area, by promoting knowledge and learning capabilities due to requirement for the implementation and dissemination to potential user groups. The environmental EU policy is addressed by the increased use of new types of higher efficiency lightweight OPVs requiring less input of resources, and by reduced waste (around 50 %) of r2r production processes. Finally, the controlled production lines and improved visualisation of information will potentially improve the EU citizens quality of life.
The market of optoelectronic and electronic devices is one of the most rapidly growing sectors in today's industry. The production technology for OLED displays on flexible polymer substrates through r2r technology will expand this already flourishing market towards a series of new applications. PV devices are another fast-growing sector of optoelectronic industry. Again, the introduction of flexible PVs produced by r2r technology on polymer substrates will substantially expand the market far beyond the figures foreseen for rigid PVs.
The deployment of in-line process control on r2r machines results both in the improvement of product properties and higher process stability and in reduction of production costs by minimising and avoiding rejects, as well as in lower costs for exploitation, maintenance and quality control. Therefore, the whole strategy behind FLEXONICS represents the transition from resource intense industries (using e.g. glass, thick plastic parts, metal) towards knowledge-based industries (e.g. by incorporating intelligent and controllable processes that deliver materials with high functionality). Finally, the new optical monitoring units and platforms will also be available for other industrial sectors, such as semiconductors, biochips etc. These developments will drive sales in specialised machine systems, by a factor of some tens above the sales for the optical equipment alone, due to their enhanced performance and thus will boost the market share of European manufacturers of r2r film conversion equipment. Such a trend will strengthen the competitiveness of the participating companies and especially their customers (mainly SMEs) on an international level, maintain technical and economical leadership and improve employment across Europe.
FLEXONICS contributes to the standardisation by defining typical figures of merit, for example:
- in efficiency and power generation for solar cell test-devices. The development of new fabrication methods will have a positive impact on quality standards and environmental norms for industrial production.
- new standards in the measurement limits, modelling and analysis methodology established.
- expand the current limits for water vapour transmission and establish new standards in the measurement resolution.
- new methodology for the offline measurement of oxygen and water vapour at low permeation that is based on a photochemical sensing system.
Website
The FLEXONICS website has been created to act as a permanent dissemination channel, updated with reports on progress and results emerging from FLEXONICS. It also provides a mechanism for interested parties to contact the appropriate FLEXONICS partners in order to find out more about the project or its results. The website is: http://www.flexonics.org
