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Continuous R2R Coating Methodology to Manufacture Precision Microstructures
for Displays, High-Brightness LEDs, Traffic Signs, Solar Concentrators and other
Light Management Products
October 25, 2006
10x Technology, LLC Bringing Advanced Materials to Life
Micro-replication forms microscopic structures on the surface of a substrate such
as plastic film
§ Micro = smaller than unaided eye can see
§ Replicate = to copy continuously and accurately
Industry demands a high degree of precision, such as nano-scale accuracy for
optical products.
Typical tolerance specifications:
§ Angles accurate to 1.0 minute of arc
§ Surface flatness controlled to ¼ wavelength of light (0.07µm)
What is Micro-Replication?
DISPLAYS
TRAFFIC SIGNS
DRUG DELIVERY
MICROFLUIDICS
SOLAR COLLECTORS
Examples of Micro-Replicated Products
In 1986 the first micro-prismatic retro-reflective films for the traffic control market was commercialized by Stimsonite Corporation
Reflective Sheeting
SEM showing micro-prismatic structures in reflective sheeting for road signs
(22,000 Micro-Prisms per square inch)
Example of Micro-Replication
In 1993 the same technology produce the first pre-production prototypes of Brightness Enhancing Film (BEF) for flat panel displays; now a $3.0 billion market annually
Optically Precise BEF V-Grooves
Brightness Enhancing Film
Example of Micro-Replication
The Two Recognized Commercial Micro-replication Platforms
Hot Polymer Embossing
• Melt the polymer substrate then pressure “Emboss” on to a cylindrical mold
Cast & Cure
• Liquid-casting of polymers on to a cylindrical mold then radiation cure
Flexible metal belt (Mold)
Plastic film to be formed
Embossed film
Embossing TechnologyEmbossing Technology
MoldMoldMold
Polymer Film pressed into mold
Mold Mold
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Liquid Cast & Cure Process
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Liquid Polymer
Cylindrical Mold
Polymer Carrier Cured Polymer
Cure Source
(UV – EB – Heat)
11111111111111111111111111111111
111111111111111111111111111111111
Hot Polymer Embossing Technology
Advantages
•Uses low cost commercially available polymers
•Continuous and accurate process
Disadvantages
•Slow processing speed
•Limited to thermoplastic polymers
•Expensive mold fabrication
•Long mold fabrication time from a master to production tooling.
(Reduces the time to market)
Liquid Cast & Cure Process
Advantages
•High process speed
•Continuous and accurate process
Disadvantages
•High raw-material cost
•Expensive mold fabrication
•Long mold fabrication time from a master to
production tooling
•Extensive Intellectual Property Coverage
•IP is generally unavailable for licensing
• The process enables the creation of entirely new classes of products outside the scope of existing technology by allowing for:
– Thicker substrates
– Higher performance polymers
– Unique geometries
– The ability to use material combinations rather than one substrate
– Reduces capital expense and footprint
• Disruptive, patent-pending manufacturing process to address current demands and new market opportunities
The NewThe New Process TechnologyProcess Technology
Powder-coating fills the mold from the bottom-up without air entrapment dramatically increasing manufacturing speed
New Process Technology
Compared to the “Cast and Cure” Process
• Customers can use own selected polymers (Commercially Available polymers or custom formulations)
• Can work with thicker substrates
• Reduced material cost (50% savings)
• Ability to address smaller initial market size
• Clean IP
Compared to the Embossing Process
• Ten times the speed advantage
• Can produce thicker and ridged designs
• Flexibility in choice of materials
• Reduced floor space, equipment cost, material cost
Relative Advantages the New TechnologyRelative Advantages the New Technology
Next-Generation
Brightness Enhancing Films
• RFID chip manufacturing
• Privacy screens for laptops
• Fiber optic light-guides
• Large display flat screens
Other Applications
Reflector Arrays for Efficient LED Lighting
Emerging Markets
Traffic-Control Products
Semiconductor/Electronic
Component fabrication Reflector arrays for LED lighting
Micro-fluidics for medical diagnosticsMicro-needles for drug delivery
Emerging Markets
Micro-Fuel Cell Components
CMP (Chemical Mechanical Planarization)
Solar Collectors
Other Applications
• Lighting (Light Pipe Guides)
• Thin film batteries
• Sky-lights
Emerging Markets
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10x Technology, LLC Bringing Advanced Materials to Life
Robert Pricone President
10x Technology LLC2105 Tempel Drive
Libertyville, IL 60048Phone: (847) 549-6283Fax: (847) 557-9164
Please feel free to contact us with specific questions regardingapplications for this technology.