Roll-to-Roll Inkjet and Photonic Sintering Integration for Printed Electronics · 2019-10-04 ·...
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Roll-to-Roll Inkjet and Photonic Sintering Integration for Printed Electronics AIMCAL R2R USA Myrtle Beach, SC October 2019 Stan Farnsworth Chief MarketingOfficer
Transcript of Roll-to-Roll Inkjet and Photonic Sintering Integration for Printed Electronics · 2019-10-04 ·...
Roll-to-Roll Inkjet and Photonic Sintering Integration for
Printed Electronics
AIMCAL R2R USAMyrtle Beach, SC
October 2019
Stan Farnsworth
Chief MarketingOfficer
Enabling Electronics for a Curved World
PulseForge® Photonic Curing Systems
Metalon ® Conductive Inks
Inks vs Substrates: Solving ThermalMismatch
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Using carefully timed and controlled flashlamps to heat only the surface and not the entire thickness of the material. Exposure time is usually less than 1 millisecond.
Heating Just the Inks: Photonic Sintering
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As Printed After Processing
Pulse Shaping
Conventional Pulse Pulse Shaping
Pulse Shaping: Multiple pulses acting within the thermal equilibrium time of the material.• Equivalent energy but composite pulse allows better control of temperature profile.• Preferred pulse structure for many thicker depositions as well as for drying.
It’s Not All About Power --But itHelps!
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Radiant Power of PulseForge vs. Traditional Flashlamp Systems
PulseForge
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• High peak radiant power (nearly 10X greater than a traditional flashlamp system) is critical for achieving a substrate-saving thermal gradient.
Beam Pattern: Quality Matters
20 mm X 300 mm (Traditional)
75 mm X 150 mm (PulseForge X2)
75 mm X 300 mm (PulseForge X4)
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Up to 4.8m wide
Material Travel Direction
Beam Uniformity: Transverse Direction
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Intensity Distribution --Traditional1
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Intensity Distribution --Traditional
FPFP + 1cm FP + 2 cm
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Intensity Distribution --PulseForge1
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Intensity Distribution --PulseForge
Beam Uniformity: Longitudinal Direction
• The PulseForge beam has ~10X more uniformity in the longitudinal direction as well.• Capable of operating with much tighter process windows.• Higher quality and yield.
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Intensity Distribution --Traditional
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Intensity Distribution --PulseForge
Transitioning from S2S to R2R: Stitching
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• Moving from single exposure
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• Overlap peaks can damage materials.
Engineering for Overlap (R2R Scaling)
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• Wider beam• 10X better uniformity• 50% less sensitive to focal point
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Why Inkjet for PE? Digital Manufacturing
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• Non-contact deposition
• Quick design changeover
• Format Flexibility
• Speed
• Just-in-time and highly customized manufacturing
Inkjet offers unique benefits to pilot and small-to-medium scale manufacturers.
Integrating into R2R with Conductive Inkjet
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• Two arrays of 3 Fujifilm Dimatix Samba heads• Duplicate arrays allow for increased coverage and redundancy
• 8kW Adphos multi-zone IR dryer
• PulseForge® photonic curing/sintering tool
Inkjet R2R Conductive Ink Integration
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• Stop-start reliability• Turn-key system component matching
JS-A191 Print Measurement
300 µm wide trace~ 3 µm height
• Prints with Dimatix DMP: 250 µm wide trace at 20 µm drop spacing• Profilometry with Keyence VK-X system
Visible Image Height Heat MapCross Section
JS-A191: Multi-layered Films
Fully processed on the PulseForge tools
Drying Pulse
17x
Sintering Pulse
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Used 30 µm spacing
Capabilities for R2R Inkjet System
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Configuration Type Two-row piezo IJ, single-layer pattern/pass, edge control, tension control
Maximum image width 5 inches / 125mm Can be scaled by adding additional print heads
Print head resolution 1200 dpi Effectively less for redundancy (~400-600 dpi)
Minimum line width 200 microns - Currently limited by web weave- Expected to reach 50 micron near future
Linear production speed 10 meters/min Limited by nIR dryer power/energy rating
Typical electrical performance 25 mOhm/sq Largely a factor of ink type and
deposition thickness
Dimensions 120”L x 48”W x 68” T
Key equipment vendors Dimatix (Samba IJ), Adphos (nIR), NovaCentrix (Metalon inks, PulseForge)
Inkjet R2R Conductive Ink Integration
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Video clip of operating tool and printed product
Is Inkjet PE a Good Customer Fit?
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• Do the required electrical properties align with current IJ capabilities?
• Does the job require high speed, and many different patterns and small batches?
• How close is the IJ tool customer to their end customer - is this a just-in-time and small or medium (or pilot) scale production?
• Would a traditional printing process be cost an space prohibitive?
• Ignore the linked-system relationships with peril – inks and equipment are not necessarily interchangeable with other “similar” inks or tooling types.
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Thank you
Charles Munson
CEO/President
Rick Larson
Manager, Technical [email protected]
www.novacentrix.com
Stan Farnsworth
Chief Marketing Officer
Ian Rawson
Applications Engineer
