Community Research and Development Information Service - CORDIS


ROLL-OUT Report Summary

Project ID: 644631
Funded under: H2020-EU.

Periodic Reporting for period 2 - ROLL-OUT (High-performance, Flexible, AUTOnomous Systems manufactured with Unique, Industrial ROLL-to-roll equipments)

Reporting period: 2016-01-01 to 2016-12-31

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, low-temperature, roll-to-roll processes, namely sputtering, atomic layer deposition (ALD), and printing in addition to evaporation and lift-off etching on thin, flexible, large-area substrates. Exemplary representations of the envisioned autonomous systems are shown in Fig. 1. This will enable enormous value addition to the products of European industries without adding any significant extra cost. Participation of industrial partners from multiple business areas (ILAB for consumer product packaging, Maier for automotive components and systems and FoV for smart textiles) justify the relevance and support maximum impact of the ROLL-OUT project.

Scientific objectives:
1. Indium-free oxide transistors fabricated on flexible substrates, exhibiting mobility above 20 cm2/Vs with excellent stability under light and negative gate bias stress (ΔVT<0.5 V after 1h stress).
2. Roll-to-roll (R2R) printed integrated circuits with operational amplifier and differential amplifier based on In-free semiconductor oxide transistors.
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.
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.
9. Large area distributed pressure sensors will be integrated between different layers of car sat textiles for measuring occupancy and weight of the passenger.
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

Project Roll-Out started on 01.01.2015 and has completed 2 years on 31.12.2016. The project has minor deviations in the scheduling of the technical progress but is still on-track, both financially and also technically regarding reaching the main objectives. However, it has been evaluated that the pressure sensor application especially for consumer liquid bottles is not commercially justifiable (See D4.2) and that the capacity target of the printed batteries will likely be too high. The deviations from the milestones are evaluated below in Table 2. On the other hand, the project has already tested all the R2R fabrication steps at 30 cm web width that corresponds to pilot fabrication lines, for example, at VTT. All the project partners – both research organizations and industrial partners, have contributed positively towards the accomplishments of the tasks and all deliverables have so far been submitted according to schedule or with minor delays of few days or weeks. In this report we briefly summarize the technical activities undertaken and/or accomplished till-date in the project. Details of the technical activities are provided in the submitted deliverables, hence will not be elaborated in detail in this report.
The main results achieved so far are:
• Definition of the smart bottle and car door handle use cases including demonstrator and electronics design and testing of the electronics functionalities (see D4.2, D3.3 and D1.6). The construction and testing of the demonstrators is planned for the final project period.
• Lab-scale sputtered indium-free zinc-tin oxide (ZTO) thin-film transistors (TFTs) fabricated on flexible PEN foil with maximum processing temperature of 180 °C having comparable performance to state-of-the-art indium-gaIlium-zinc oxide (IGZO) TFTs: µFE=7 cm2/Vs, Von=-0.5 V, On/Off ratio >106, S=0.3 V/dec (as Dec 2016, article under publication).
• Successful design and simulation of complete readout circuitry for fill-level monitoring, entirely based in oxide TFTs. The system has a significant complexity (182 transistors, divided in analogue and digital blocks), showing the potential of oxide electronics to go well beyond the conventional switching and current driver elements of displays. Fabrication of first batch resulted in successful characterization of clock generator, phase generator and capacitance-to-voltage converter. New batch scheduled for January 2017.
• Completion of first fully roll-to-roll process for thin film transistors and circuits combining printing, evaporation, lift-off, sputtering and ALD fabrication steps. Based on the results, second R2R fabrication round is being started in January 2017.

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 impact of ROLL-OUT is still in accordance with the DoA. Outlook of reaching the impact is evaluated in the project annually in deliverables D6.5 - 6.7. This will quantitatively define the exploitation plan of the outcome of the project. This roadmap document includes plans for all 5 industrial partners participating in the project. This includes original equipment manufacturers (PICOSUN, POLYTEKNIK) and end-users (LOGOPLASTE, MAIER and FOV).
It is expected that the project will demonstrate new product concepts in three different application areas that are the smart packaging (ILAB bottle for consumer drinks sensing the fill level and temperature), car interior (Maier flexible sensors for window control in door handle) and smart textiles (FOV car-seat pressure sensor / ECG vest / lash warner). Cost efficient commercialization of these is expected to be enabled by the project large-area processing developments that expand the availability of different processing techniques in roll-to-roll fabrication. Namely, the target is to enable combining sputtering and ALD with printing, evaporation and lift-off etching such that the process that is most competent for a particular device layer or circuit element can be used for that purpose. Printed electronics and flexible thin-film electronics that these developments are linked to represent emerging markets with significant growth potential as regularly illustrated by market analysis companies such as IdTechEx, Frost & Sullivan and Yole Development.

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