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Photonic Curing Explanation and Application to Printing Copper Traces on
Low Temperature SubstratesK. A. Schroder
October 2011
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www.novacentrix.com
Abstract
NovaCentrixs PulseForge tools perform high temperature
processing of thin films on low temperature substrates such
as paper and plastic in milliseconds at speeds beyond 100
m/min in a wide web format using a unique process known
as Photonic Curing. This flashlamp-based technology dries,
sinters, anneals, and even modulates chemical reactions.
The mechanisms and limitations of this process are
presented along with an example of reducing a CuO based
ink on plastic and paper
2
PresenterPresentation NotesNovaCentrix PulseForge tools can process high temperature materials on polymer and paper at high speed. This talk will focus primarily on forming low cost conductors on plastic and paper with the Photonic Curing process.
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www.novacentrix.com 3
NovaCentrix in the Supply Chain
Printed Electronics Manufacturing
NovaCentrix Technologies and Products
RawMaterials
MfgMaterials
CuringTools
Device/Application
Ink components;Raw substrates
Inks;Substrates
Roll-to-roll;Conveyors
Inkjet;Screen;Aerosol;Flexo;Gravure;
Ovens;Air knives;New Tech
Ovens;UV Lamps;Lasers;PulsedThermal Processing;New Tech
Solar;RFID;Batteries;Transistors;Displays;Packaging;Smart cards
MaterialHandlers Printers Dryers
Tool Integrators
Nanoparticles Metalon inksNovele substrates
PulseForge toolsSimPulse thermal simulator
Industryproduct types
1999 2006 2006
2010
Commercialrelease
PresenterPresentation NotesNovaCentrix was founded in 1999 as a nanotechnology company.Expertise in nanomaterials, pulsed power, equipment design, electronic inks.Creative technology team has developed an extensive patent portfolio.We bring our expertise to our customers to generate value for them by helping them solve their problems.Since NovaCentrix is involved in several parts of the supply chain, it is able to provide better value to its customers by understanding their problems.Our long history and experience with nanotechnology enables vertical integration of our products.
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www.novacentrix.com
Recognition and Honors
PulseForge tools2009: R&D 100 recipient in partnership with Oak
Ridge National LaboratoryShipped PulseForge 3300 #001 to customer
2008: Best Development: Manufacturing by IDTechEx for PulseForge 3100
Metalon ICI copper-based inks2011: Finalist: Technology of the yearby AIMCAL2010: R&D 100 recipient
Best Development: Materials by IDTechEx2009: Labeled Game Changer by Printed
Electronics World
2009PulseForge 3100 and Pulsed Thermal ProcessingWith Oak Ridge National Laboratories
Technical Development: Materials2010
2010Metalon ICI Low-Cost Copper Inks
2011Technical ExcellenceMetalon ICI ICI-020
PresenterPresentation NotesNovaCentrix has been honored for both equipment development and materials development.
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www.novacentrix.com 5
Photonic Curing
Photonic Curing was first introduced at NSTI in 2006.
It is the use of a flashlamp to transiently heat a thin film to high temperature on a low-temperature substrate without damage.
First used to sinter nanosilver and nanocopper inks on plastic and paper.
PulseForge 3300 Photonic curing is fundamentally a transient thermal process and includes
sintering, annealing, drying, crystallization, polymerization, chemical reaction initiation and modulation, dopant drive-in, degasification, etc.
It has become a key enabler to printed electronics as it has enabled high speed processing of high temperature materials on cheap low temperature substrates such as plastic and paper.
Technology has been scaled to process roll to roll materials in a wide web format at speeds up to 100 m/min.
PresenterPresentation NotesPulseForge tools can cure many other materials not discussed in this presentation.
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www.novacentrix.com 6
PulseForge: Simple Beginnings
Inspired by a camera flash which has properties of:
Moderate power: 2 kW/cm2 Low energy: 1 J/cm2 Suitable for certain types of nanoparticle
processing on low temperature substrates
PresenterPresentation NotesSmall flash camera can sinter nanosilver on paper or plastic. A video of flash camera initiating the combustion of nanoaluminum is at http://www.youtube.com/watch?v=AJFIoSrvanQ
However, existing industrial flash lamp systems have inadequate beam quality, control, and speed for industrial Photonic Curing processing.
New technology was developed to make PulseForge: a web-autosychronized flashlamp system with high power, large area, high uniformity, high speed, and electronic pulse control.
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www.novacentrix.com 7
PulseForge: Simple Beginnings
PresenterPresentation NotesSmall flash camera can sinter nanosilver on paper or plastic. A video of flash camera initiating the combustion of nanoaluminum is at http://www.youtube.com/watch?v=AJFIoSrvanQ
However, existing industrial flash lamp systems have inadequate beam quality, control, and speed for industrial Photonic Curing processing.
New technology was developed to make PulseForge: a web-autosychronized flashlamp system with high power, large area, high uniformity, high speed, and electronic pulse control.
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www.novacentrix.com 8
PulseForge: Simple Beginnings
Inspired by camera flash which has properties of:
High power : 2 kW/cm2 Low energy: 1 J/cm2 Suitable for certain types of nanoparticle
processing on low temperature substrates
But camera flash needs improvement for use in printed electronics
Poor controllability Limited power and energy Erratic output Not well suited for use in roll-to-roll production
New Technology needed to be developed beyond current industrial systems. Needed the control of laser processing, but the economics of oven processing.
The result was PulseForge!
PresenterPresentation NotesSmall flash camera can sinter nanosilver on paper or plastic. A video of flash camera initiating the combustion of nanoaluminum is at http://www.youtube.com/watch?v=AJFIoSrvanQ
However, existing industrial flash lamp systems have inadequate beam quality, control, and speed for industrial Photonic Curing processing.
New technology was developed to make PulseForge: a web-autosychronized flashlamp system with high power, large area, high uniformity, high speed, and electronic pulse control.
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www.novacentrix.com
PulseForge Tools
Designed and built specifically to solve the thermal problem.The tools use intense pulsed light to heat functional inks and thin films without damaging temperature-sensitive substrates like plastic films and paper. This process is known as Photonic Curing.
Designed for development and production use. Developed in cooperation with Oak Ridge National Laboratory. > 10 US and international patents issued or pending relating to using flash
lamps to sinter nanometal inks on low temperature substrates as well as other processes enabled by this technology.
Materials processingDryingSinteringAnnealingReacting
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PresenterPresentation NotesPulseForge tools use Photonic Curing. This intense pulsed light technology has many applications to thin film processing including: Drying, sintering, annealing, and reacting thin films. These processes can all be performed on low cost, low temperature substrates such as paper or plastic at high speeds compatible with roll to roll manufacturing.
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www.novacentrix.com 10
Typical Thermal Profile
High temperature processing removes excess solvent and enhances sintering. Substrate is undamaged.
0100200300400500600700800900
10001100
0 5 10 15 20 25 30 35 40t [ms]
T [C
]
Surface20 micron from surface150 micron from surfacePeak temp >1000 C
Substrate < 150 C @ 8 ms Thermal equilibrium @ 35 ms (90C)
Conditions:1 m Ag Film on 150 m(6 mil) PETRadiant exposure: 1 J/cm2Pulse length: 300 s
Ag Film
PET
SimPulseTM Numerical Simulation
PresenterPresentation NotesThin film can be silver particles, copper particles, or even semiconductors or ceramics!Ordinarily, PET can only be heated up to 150 C.Using PulseForge tools, a thin film can be heated to over 1000 C on ordinary PET without damaging the PET.This type of processing can achieve higher performance in a functional thin film over a conventional oven.Processing is so fast that it can be synchronized to a web and cured on a roll to roll system at speeds beyond 100 m/minute.
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93.5493.1284.41
93.5393.1184.42
93.5293.184.43
93.593.0984.44
93.4993.0884.46
93.4893.0784.47
93.4793.0684.48
93.4693.0584.49
93.4493.0484.5
93.4393.0284.51
93.4293.0184.52
93.419384.53
93.492.9984.54
93.3992.9884.55
93.3892.9784.57
93.3692.9684.58
93.3592.9584.59
93.3492.9484.6
93.3392.9384.61
93.3292.9284.62
93.3192.9184.63
93.392.984.64
93.2892.8984.65
93.2792.8884.66
93.2692.8784.67
93.2592.8684.68
93.2492.8584.69
93.2392.8484.7
93.2292.8384.71
93.2192.8284.72
93.1992.8184.73
93.1892.884.75
93.1792.7984.76
93.1692.7884.77
93.1592.7784.78
93.1492.7684.79
93.1392.7584.8
93.1292.7484.81
93.1192.7384.82
93.192.7284.83
93.0992.7184.84
93.0792.784.85
93.0692.6984.86
93.0592.6884.87
93.0492.6784.88
93.0392.6784.89
93.0292.6684.9
93.0192.6584.91
9392.6484.92
92.9992.6384.93
92.9892.6284.94
92.9792.6184.95
92.9692.684.96
92.9592.5984.97
92.9492.5884.98
92.9392.5784.99
92.9292.5685
92.9192.5585.01
92.992.5485.02
92.8892.5385.02
92.8792.5285.03
92.8692.5285.04
92.8592.5185.05
92.8492.585.06
92.8392.4985.07
92.8292.4885.08
92.8192.4785.09
92.892.4685.1
92.7992.4585.11
92.7892.4485.12
92.7792.4385.13
92.7692.4285.14
92.7592.4285.15
92.7492.4185.16
92.7392.485.17
92.7292.3985.18
92.7192.3885.18
92.792.3785.19
92.6992.3685.2
92.6892.3585.21
92.6792.3485.22
92.6692.3485.23
92.6592.3385.24
92.6492.3285.25
92.6392.3185.26
92.6392.385.27
92.6292.2985.28
92.6192.2885.28
92.692.2885.29
92.5992.2785.3
92.5892.2685.31
92.5792.2585.32
92.5692.2485.33
92.5592.2385.34
92.5492.2285.35
92.5392.2285.36
92.5292.2185.36
92.5192.285.37
92.592.1985.38
92.4992.1885.39
92.4892.1785.4
92.4792.1785.41
92.4692.1685.42
92.4692.1585.42
92.4592.1485.43
92.4492.1385.44
92.4392.1285.45
92.4292.1285.46
92.4192.1185.47
92.492.185.48
92.3992.0985.48
92.3892.0885.49
92.3792.0785.5
92.3692.0785.51
92.3592.0685.52
92.3592.0585.53
92.3492.0485.53
92.3392.0385.54
92.3292.0385.55
92.3192.0285.56
92.392.0185.57
92.299285.57
92.2891.9985.58
92.2791.9985.59
92.2791.9885.6
92.2691.9785.61
92.2591.9685.62
92.2491.9685.62
92.2391.9585.63
92.2291.9485.64
92.2191.9385.65
92.2191.9285.66
92.291.9285.66
92.1991.9185.67
92.1891.985.68
92.1791.8985.69
92.1691.8985.69
92.1591.8885.7
92.1591.8785.71
92.1491.8685.72
92.1391.8685.73
92.1291.8585.73
92.1191.8485.74
92.191.8385.75
92.0991.8385.76
92.0991.8285.76
92.0891.8185.77
92.0791.885.78
92.0691.885.79
92.0591.7985.79
92.0591.7885.8
92.0491.7785.81
92.0391.7785.82
92.0291.7685.82
92.0191.7585.83
9291.7485.84
9291.7485.85
91.9991.7385.85
91.9891.7285.86
91.9791.7185.87
91.9691.7185.88
91.9691.785.88
91.9591.6985.89
91.9491.6985.9
91.9391.6885.91
91.9291.6785.91
91.9291.6685.92
91.9191.6685.93
91.991.6585.93
91.8991.6485.94
91.8891.6485.95
91.8891.6385.96
91.8791.6285.96
91.8691.6285.97
91.8591.6185.98
91.8591.685.98
91.8491.5985.99
91.8391.5986
91.8291.5886.01
91.8191.5786.01
91.8191.5786.02
91.891.5686.03
91.7991.5586.03
91.7891.5586.04
91.7891.5486.05
91.7791.5386.05
91.7691.5386.06
91.7591.5286.07
91.7591.5186.08
91.7491.5186.08
91.7391.586.09
91.7291.4986.1
91.7291.4986.1
91.7191.4886.11
91.791.4786.12
91.6991.4786.12
91.6991.4686.13
91.6891.4586.14
91.6791.4586.14
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91.6691.4386.16
91.6591.4386.16
91.6491.4286.17
91.6491.4186.18
91.6391.4186.18
91.6291.486.19
91.6191.3986.19
91.6191.3986.2
91.691.3886.21
91.5991.3786.21
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91.5491.3386.26
91.5491.3286.27
91.5391.3286.27
91.5291.3186.28
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91.5191.386.29
91.591.2986.3
91.4991.2986.3
91.4991.2886.31
91.4891.2786.32
91.4791.2786.32
91.4791.2686.33
91.4691.2686.33
91.4591.2586.34
91.4591.2486.35
91.4491.2486.35
91.4391.2386.36
91.4391.2386.36
91.4291.2286.37
91.4191.2186.38
91.4191.2186.38
91.491.286.39
91.3991.286.39
91.3991.1986.4
91.3891.1886.41
91.3791.1886.41
91.3791.1786.42
91.3691.1786.42
91.3591.1686.43
91.3591.1586.44
91.3491.1586.44
91.3391.1486.45
91.3391.1486.45
91.3291.1386.46
91.3191.1286.46
91.3191.1286.47
91.391.1186.48
91.391.1186.48
91.2991.186.49
91.2891.186.49
91.2891.0986.5
91.2791.0886.5
91.2691.0886.51
91.2691.0786.52
91.2591.0786.52
91.2491.0686.53
91.2491.0686.53
91.2391.0586.54
91.2391.0486.54
91.2291.0486.55
91.2191.0386.55
91.2191.0386.56
91.291.0286.57
91.1991.0286.57
91.1991.0186.58
91.1891.0186.58
91.189186.59
91.1790.9986.59
91.1690.9986.6
91.1690.9886.6
91.1590.9886.61
91.1590.9786.61
91.1490.9786.62
91.1390.9686.63
91.1390.9686.63
91.1290.9586.64
91.1290.9586.64
91.1190.9486.65
91.190.9486.65
91.190.9386.66
91.0990.9286.66
91.0990.9286.67
91.0890.9186.67
91.0790.9186.68
91.0790.986.68
91.0690.986.69
91.0690.8986.69
91.0590.8986.7
91.0590.8886.7
91.0490.8886.71
91.0390.8786.71
91.0390.8786.72
91.0290.8686.72
91.0290.8686.73
91.0190.8586.73
9190.8586.74
9190.8486.74
90.9990.8486.75
90.9990.8386.75
90.9890.8386.76
90.9890.8286.76
90.9790.8286.77
90.9790.8186.77
90.9690.8186.78
90.9590.886.78
90.9590.886.79
90.9490.7986.79
90.9490.7986.8
90.9390.7886.8
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90.9290.7786.81
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90.990.7686.83
90.990.7586.83
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90.8890.7486.85
90.8890.7386.85
90.8790.7386.86
90.8790.7286.86
90.8690.7286.87
90.8690.7186.87
90.8590.7186.87
90.8490.786.88
90.8490.786.88
90.8390.6986.89
90.8390.6986.89
90.8290.6886.9
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90.8190.6786.91
90.8190.6786.91
90.890.6686.92
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90.7890.6486.94
90.7790.6486.94
90.7790.6386.95
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90.7590.6286.96
90.7590.6186.97
90.7490.6186.97
90.7490.686.97
90.7390.686.98
90.7390.686.98
90.7290.5986.99
90.7290.5986.99
90.7190.5887
90.7190.5887
90.790.5787
90.790.5787.01
90.6990.5687.01
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90.6890.5587.02
90.6890.5587.03
90.6790.5587.03
90.6790.5487.03
90.6690.5487.04
90.6690.5387.04
90.6590.5387.05
90.6590.5287.05
90.6490.5287.05
90.6490.5287.06
90.6390.5187.06
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90.6290.587.07
90.6290.587.08
90.6190.4987.08
90.6190.4987.08
90.690.4987.09
90.690.4887.09
90.5990.4887.1
90.5990.4787.1
90.5890.4787.1
90.5890.4687.11
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90.5790.4587.12
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90.5590.4487.13
90.5590.4387.14
90.5490.4387.14
90.5490.4387.14
90.5390.4287.15
90.5390.4287.15
90.5290.4187.16
90.5290.4187.16
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90.5190.487.17
90.5190.487.17
90.590.3987.17
90.590.3987.18
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90.4890.3887.19
90.4890.3787.19
90.4790.3787.2
90.4790.3787.2
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90.4690.3687.21
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90.4590.3587.22
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90.4490.3387.23
90.4390.3387.23
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90.4290.3287.24
90.4290.3287.25
90.4190.3187.25
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90.490.3187.26
90.490.387.26
90.490.387.26
90.3990.2987.27
90.3990.2987.27
90.3890.2987.27
90.3890.2887.28
90.3890.2887.28
90.3790.2887.28
90.3790.2787.29
90.3690.2787.29
90.3690.2687.29
90.3590.2687.3
90.3590.2687.3
90.3590.2587.31
90.3490.2587.31
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90.3390.2487.32
90.3390.2387.32
90.3290.2387.33
90.3290.2387.33
90.3190.2287.33
90.3190.2287.34
90.3190.2287.34
90.390.2187.34
90.390.2187.35
90.2990.2187.35
90.2990.287.35
90.2890.287.36
90.2890.1987.36
90.2890.1987.36
90.2790.1987.37
90.2790.1887.37
90.2790.1887.37
90.2690.1887.38
90.2690.1787.38
90.2590.1787.38
90.2590.1787.39
90.2590.1687.39
90.2490.1687.39
90.2490.1687.4
90.2390.1587.4
90.2390.1587.4
90.2390.1487.4
90.2290.1487.41
90.2290.1487.41
90.2190.1387.41
90.2190.1387.42
90.2190.1387.42
90.290.1287.42
90.290.1287.43
90.290.1287.43
90.1990.1187.43
90.1990.1187.44
90.1890.1187.44
90.1890.187.44
90.1890.187.45
90.1790.187.45
90.1790.0987.45
90.1790.0987.45
90.1690.0987.46
90.1690.0887.46
90.1590.0887.46
90.1590.0887.47
90.1590.0787.47
90.1490.0787.47
90.1490.0787.48
90.1490.0687.48
90.1390.0687.48
90.1390.0687.48
90.1290.0587.49
90.1290.0587.49
90.1290.0587.49
90.1190.0487.5
90.1190.0487.5
90.1190.0487.5
90.190.0387.5
90.190.0387.51
90.190.0387.51
90.0990.0287.51
90.0990.0287.52
90.0990.0287.52
90.0890.0187.52
90.0890.0187.52
90.0790.0187.53
90.0790.0187.53
90.079087.53
90.069087.54
90.069087.54
90.0689.9987.54
90.0589.9987.54
90.0589.9987.55
90.0589.9887.55
90.0489.9887.55
90.0489.9887.56
90.0489.9787.56
90.0389.9787.56
90.0389.9787.56
90.0389.9687.57
90.0289.9687.57
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90.0189.9587.58
90.0189.9587.58
90.0189.9587.58
9089.9487.59
9089.9487.59
9089.9487.59
89.9989.9387.59
89.9989.9387.6
89.9989.9387.6
89.9889.9387.6
89.9889.9287.6
89.9889.9287.61
89.9789.9287.61
89.9789.9187.61
89.9789.9187.61
89.9689.9187.62
89.9689.987.62
89.9689.987.62
89.9589.987.62
89.9589.987.63
89.9589.8987.63
89.9489.8987.63
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89.9489.8887.64
89.9389.8887.64
89.9389.8887.64
89.9389.8887.64
89.9289.8787.65
89.9289.8787.65
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89.9189.8687.66
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89.989.8587.66
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89.989.8587.67
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89.8889.8487.68
89.8889.8387.68
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89.8789.8387.69
89.8789.8287.69
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89.8689.8287.7
89.8689.8187.7
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89.8589.8187.7
89.8589.8187.7
89.8589.887.71
89.8489.887.71
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89.8489.7987.72
89.8389.7987.72
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89.8289.7887.72
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89.889.7687.74
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89.7989.7587.75
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89.7789.7387.76
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89.7789.7387.77
89.7689.7387.77
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89.7589.7287.78
89.7589.7187.78
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89.7389.787.8
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89.7389.6987.8
89.7289.6987.8
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89.7289.6887.81
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89.789.6787.82
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89.6989.6687.82
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89.6989.6687.83
89.6989.6687.83
89.6889.6587.83
89.6889.6587.83
89.6889.6587.84
89.6789.6587.84
89.6789.6487.84
89.6789.6487.84
89.6789.6487.84
89.6689.6487.84
89.6689.6387.85
89.6689.6387.85
89.6689.6387.85
89.6589.6387.85
89.6589.6387.85
89.6589.6287.86
89.6589.6287.86
89.6489.6287.86
89.6489.6287.86
89.6489.6187.86
89.6489.6187.87
89.6389.6187.87
89.6389.6187.87
89.6389.687.87
89.6389.687.87
89.6289.687.87
89.6289.687.88
89.6289.687.88
89.6289.5987.88
89.6189.5987.88
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89.6189.5887.89
89.689.5887.89
89.689.5887.89
89.689.5887.89
89.689.5887.89
89.5989.5787.9
89.5989.5787.9
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89.5889.5687.9
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89.5889.5687.91
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89.5789.5587.91
89.5789.5587.91
89.5789.5587.91
89.5789.5587.92
89.5689.5587.92
Surface
20 micron from surface
150 micron from surface
t [ms]
T [C]
1-micron-PET-graph
NovaCentrix Heat Conduction Simulation v2.0
layermaterialthicknessn_cellscell_distribution
layer1silver11000
layer2PET203600
layer3PET1304450
material properties
conductivity (W/m K)
429.00 0.0 0.0 layer1
0.24 0.0 0.0 layer2
0.24 0.0 0.0 layer3
density (gm/cm^3)
10.50 0.0 0.0 layer1
1.37 0.0 0.0 layer2
1.37 0.0 0.0 layer3
specific heat (J/kg K)
234.80 0.0 0.0 layer1
729.90 0.0 0.0 layer2
729.90 0.0 0.0 layer3
t_pulse300
q_o0.99
freq20
n_pulses1
T_top25
T-bot12
h_top15
h_bot15
To25
time_step5
t_print25
Temperature (C) vs. time (ms) for each layer
time(ms)topinterface1interface2bottom
025252525
0.025243.72237.692525
0.05322.05318.5225.0225
0.075466.29459.4125.1825
0.1517.66513.2825.7325
0.125634.63627.5226.9825
0.15676.01671.1229.1924.99
0.175776.14768.9532.5124.99
0.2812.74807.4937.0224.99
0.225900.78893.5642.7224.99
0.25934.82929.2949.5724.99
0.2751013.521006.3157.524.99
0.31018.671014.2966.4424.99
0.325904.34902.2476.324.99
0.35832.45830.9886.9724.99
0.375778.9777.7698.2624.99
0.4736.21735.29109.8224.99
0.425700.81700.04121.2824.99
0.45670.69670.02132.3224.99
0.475644.55643.97142.7424.99dfsdsdsds
0.5621.55621.04152.4124.99
0.525601.08600.62161.2924.99
0.55582.67582.26169.3824.99
0.575565.99565.62176.7124.99
0.6550.78550.44183.3224.99
0.625536.83536.52189.2624.99
0.65523.96523.67194.5824.99
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24.82599.4499.4498.478.74
24.8599.4199.4198.3878.76
24.87599.3999.3998.3578.79
24.999.3699.3698.3378.81
24.92599.3399.3398.378.84
24.9599.3199.3198.2878.86
24.97599.2899.2898.2678.89
2599.2699.2698.2378.92
25.02599.2399.2398.2178.94
25.0599.299.298.1978.97
25.07599.1899.1898.1678.99
25.199.1599.1598.1479.02
25.12599.1299.1298.1279.04
25.1599.199.198.0979.07
25.17599.0799.0798.0779.09
25.299.0599.0598.0579.12
25.22599.0299.0298.0279.14
25.2599999879.17
25.27598.9798.9797.9879.19
25.398.9498.9497.9679.22
25.32598.9298.9297.9379.24
25.3598.8998.8997.9179.27
25.37598.8798.8797.8979.29
25.498.8498.8497.8779.32
25.42598.8298.8297.8479.34
25.4598.7998.7997.8279.36
25.47598.7798.7797.879.39
25.598.7498.7497.
