opportunities in flexible, printed and hybrid electronics · 2019-10-14 · today, wearable...

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Opportunities in Flexible, Printed and Hybrid Electronics

Raghu Das, CEO, [email protected]

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Introduction to Flexible, Printed and Hybrid Electronics


What is Printed, Organic, Flexible Electronics?

Materials

Manufacturing technique

Product feature

Conventional Electronics

“Printed Electronics”

Low temperature:Organic polymers,Metalic inks

Printed on plastic, textiles, paper, foil

Flexible, robust, large area

High temperature:Silicon, Ceramics, Glass

Photolithography, micromachining, ablation, etc.

Rigid, brittle, miniature

Usually Subtractive Usually Additive


What is Printed, Flexible, Organic Electronics?Enabling materials and

manufacturing processes......creating these devices... ...being exploited by these

industries……because benefits can

include…

• Metallic ink • Organic semiconductors• Inorganic semiconductors• Dielectrics• Carbon nanotubes, graphene• Conductive polymers• Glass, polymer, paper and

steel substrates• Flexible barrier films,

adhesives, encapsulants• Quantum dot materials• Printing processes (inkjet,

gravure, flexo, screen, roto-screen, dip pen nanolithography, lithography)

• Vacuum deposition, spin coating, ALD, CVD, sputtering

• Sintering, curing (photonic, heat, UV, IR)

• Thin Film Transistor Circuits (TFTs)

• Memory• Displays (OLED, e-paper,

electrochromic, electrowetting, electroluminescent)

• Lighting (OLED, LED)• Sensors (photo detectors,

temperature, pressure, bioelectronic, etc.)

• Photovoltaics (CdTe, CIGS, DSSC, OPV)

• Batteries, supercapacitors• Transparent conductive films• Actuators and haptics• RFID• New Products• Stretchable electronics• Touch screens

• Healthcare• Consumer Goods• Consumer Electronics• Aerospace and Military• Media & Advertising• Architecture & the Built

Environment• Transportation

Lowcost

NEW FORM FACTORS

flexible, thin, 3D conformal, transparent, stretchableTECHNICALLY

SUPERIORe.g. better displays,

readability in sunlight, PV more efficient

in lower light levels, bio-compatible

PRODUCTIONLarger areas,

faster customization and turn around


Why do Industries Want Printed & Flexible Electronics?


Copycat products

Brands seek differentiation

“Shrinkage is $60 billion yearly of $3 trillion turnover.” ECR Europe

Stock-outs at retailers cost 6% of sales

More information is needed on the package

The package must sell the product

Problems in the Retail & Packaging Industry


How printed and flexible electronics is addressing these challenges


Two thirds of the people who have ever reached the age of 65 are alive today

Need to self-diagnose and self-treat: not enough carers, doctors or nurses

“Medication non-compliance costs the US alone approximately $100 billion and 125,000 deaths yearly”

Tens of millions of children under the age of five die every year from food related illness. UN

Need for fast, accurate diagnosis e.g. glucose level, heart rate monitor…

Problems in Healthcare

Source : National Statistics


Peak ICE

Europe

Huge Change in the Automotive Industry

China (anticipated)

India

UK

TaiwanAsia

Americas

Government restrictions: No new Internal Combustion Engine (ICE) car sales

Norway

France

Germany(anticipated)

Israel

Ireland

Austria

Netherland

Costa Rica(start phase-out)

Europe

Mexico city only(diesel only)

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Electric Vehicles: The Automotive Melodrama1. Peak Internal Combustion Engine (ICE) car sales reached? (meanwhile EV sales grow)

2. Peak car by 2030 due to autonomous vehicles Transport As A Service

460

906

94

1100

855

90

1000

367

97

2040

2029

2019

Electric Car Electric Bus/Truck Other EV

Mostly Autonomous

$ Bn


How printed and flexible electronics is addressing these opportunities

Boeing use a printed electronics system for bird strike detection

Flexible PV is lightweight enough to go on car surfaces

Mechanical switches and copper wiring replaced by a molded one piece printed system

Heating systems

Automotive Seat Heater

Energy Independent Robotic Weeder


Today, wearable electronics is mostly boxes of electronics you strap to yourself

There has been rapid commoditization in some sectors

Flexible electronics will provide a strong differentiator

Problems with Wearable Technology



Respiration sensors detecting changes in dimensions of the conductive track induced by breathing

US Winter Olympics Jackets that are heated

Activity tracking functionality (HRM, EMG, etc.) by Clothing+ and DuPont

Vista Medical

Rest Devices

BlueSpark


Smart phone sales have peaked.

Consumers want greater personalization. Smaller batch quantities, higher number of product lines.

Incremental desirable improvements are thinner devices, more robust devices, thinner edge bezels around screens, longer battery life…

Problems in Consumer Electronics

Source: IDC/Statistica

Smart Phone Sales



Apple watch has an OLED display on plastic to be thinner, and more robust

Samsung Galaxy Note Edge: has a wrap-around OLED display (rigid plastic) with a 7 mm bending radius at the sharpest point.


Printed & Flexible Electronics Technologies and their Application

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Source: JOLED

19

Printed, Flexible and Organic Electronics

Logic, Batteries, OPV, E-textiles $81M

2019$37.1bn

Conductive Ink $2.3Bn

Sensors $3.9Bn

Displays $30.8Bn

OLED Lighting $25M

Increasing Vertical/Systems Focus

Source: Blue Spark

Disruptive Products Come to Market

Printed Displays Commercialize

Source: JOLED, ynvisible

The Rise of Flexible and Foldable Displays

Source: Royole Corporation

Stretchable Electronics Grows

Source: DuPont

Source: PolyPhotonix


Screen Printing Dominates in Commercial Devices

Printed glucose test strips, force sensors, PV bus bars, touch panel electrodes, membrane circuits, heating elements

~ 98%

~ 2%

Touch panel electrodes

Glucose test strips

Solar PV bus bars and fingers


Linewidths have reduced to

<30um in production. Thinner

screen printed line widths have

been demonstrated

Main improvements are better

packing, large crystal/grain sizes

and smoother lines

Smooth lines remove

conductivity bottlenecks and large

grains reduce inter grain contact

resistance

Printed conductive ink/paste: huge progress

Source: Heraeus and others


De-Facto

Polyimide HS PET PET

Medium toC t<150oC t<120oC

LOWER COST

HIGHER COST

Conductive Ink/Paste: New OpportunitiesEMI Shielding

Heat Management

Low Temperature Solder

0%

50%

100%

2019 2029

Conductive pen

Transparent conducting layerSensors

EMI shielding in consumer electronicsSintered nano Ag die attach pasteOther

IME inks

Touch screen edge electrodeAutomotive

Silicon solar panels

$2,308 $3,225


Structural Electronics

Rapid customization, material & component cost reduction, light-weighting and saving space are key drivers

Structures become functional components

3D Surface Printing

In MoldElectronics

“Components in a Box”

1900

2016

Structural Electronics

Smart Skins

Load-bearing Components

Energy Harvesting skin

Source: UW-MadisonSource: Volvo

Load-Bearing Supercap

Source: Testo

Surface Electronics


New In-Mold electronic inks withstand thermoforming Example: integrated capacitive sensors and antennasSimplified assembly process with only a single connection point and no wires behind the console. Weight reduction is of particular interest for the automotive industry

In-Mold Electronics

Source: DuPont Source: TactoTek

24


In-Mold Electronics Comes to MarketFunctional Materials Meet New Demands

Source: TactoTek

Source: ADSSource: SINTEX NP


New Form Factors: Stretchable Electronics

2019 E-Textile Market: $224 million

E-Textiles $2.2 Bn in 2028

Sports / Fitness Health & Medical Heated Other Apparel Industrial & Military Home Other

$54mn $45mn $26mn $31mn $36mn $7mn $22mn


Flexible/Rigid plastic OLED displays over take glass based displays in 2020

0100200300400500600700800900

1000

2019 2020 2021 2022 2023

Total number of units by form factor

Glass based Flexible / Rigid plastic basedFlexible / Foldable

No.

of U

nits

, Mill

ions

Source: Xiaomi

Source: Royole

OLED Displays: From Rigid to FlexibleRe-invent products. Create new products.


Key components needed for flexible AMOLED displays

Substrate

TFTElectro-Optic Medium

Top Electrode

Encapsulation

Hard Coating/Anti Scratch

Opt. Touch Sensor


Transparent Conductive

Layer

On GlassNot considered here

On Film

TCF

ITO

Incumbent

Metal mesh

Leading alternative

Etched

No printing

Hybrid

Part printing

Direct printing

Full printing

Silver nanowire2nd leading alternative

PEDOT

Go niche?

CNT

Go niche?

Graphene

Too little too late?

Different Transparent Conductive Films (TCFs)

Level of quality, ITO on PET

Film price (2018)

Tier two supplier (low quality

10-11 $/sqm

Higher quality 14-15 $/sqm

Nitto Denko quality 16-18 $/sqm

ITO Film Price Collapse

New applications include transparent heaters, transparent antennas, In Mold Electronics, LED films


Major trends: embedded touch changes opportunity for touch film

Emerging/Growing

??

Established

Rigid Flexible

TFT/OLED Stack

TFT/OLED Stack TFT/OLED Stack TFT/OLED Stack


Printed OLEDs are finally commercial

80PPI

31

The problem: Thermal evaporation and fine metal mask (FMM) are difficult to scale to large areasSuitable for larger sized OLEDs (e.g. TV) due to printing resolution


Challenge: got to market second!Small quantities, premium priced lamps and panels, experimental design kitsLED lighting is less than a tenth of the costDifferentiation struggleR2R vs S2S?Solution processing vs. evaporation?Konica Minolta have developed Flexible OLED lighting manufacturingLG Display and OLED Works have sheet to sheet processing on glass but these can be transferred to flexible substrates

Success Eludes Flexible OLED Lighting

http://www.lumiotec.com/product/index.html


Based on OLED technology, PolyPhotonix has developed a non-invasive, monitored treatment for one of the principal causes of blindness in the western world, Diabetic Retinopathy.

The OLED device provides the actual treatment, potentially disrupting a multi billion dollar market for current treatments.

Enabling Billion Dollar Disruptive Products

33

Vs.


Electrophoretic Displays: Race for Colour>$500 million market for e-paper in 2018

B/W or Colour filters >> Spot Colour >> Full ColourNOW NOW R&D

Electrochromic displays• Printed, low power displays• Lightweight, flexible• Increasing range of colours

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Printed and Flexible Sensors Mass production Expanding production capacity

Biosensors (glucose test strips) Organic photodetectors

Piezoresistive (force sensors) Electrochemical gas sensors

Capacitive Temperature

Piezoelectric Humidity

E-textile heart rate monitors Non glucose / non cardiac biosensors

Flexible & Printed Strain Sensor

Flexible & Printed Light Sensor

Flexible & Printed Temperature Sensor

Flexible & Printed Pressure Sensor


Healthcare: Shift to Continuous Monitoring

Continuous heart rate monitoring skin patch

Acc

urac

y pe

r tes

t

Frequency of Sampling and/or User comfort

Electronic skin patch

market: $6 Bn in 2019 to $10

Bn in 2022


Cardiovascular monitoring

Diabetes management

Iontophoretic skin patches

Temperature sensing

Sweat sensing

Motion sensing

Wound monitoring and treatment

Multi sensing platforms

Other applications

37

Electronic Skin Patches: Commercial progress by form factor

5Successful product

with significant market penetration/creation

4Product launch with

moderate market penetration/creation

3Commercial product,

but limited market penetration/creation

2 Pre-commercial product

1 Research or proof-of-concept only

Electronic box with limited flexibility, attached to the skin

Close fitted design, but still relatively limited flexibility

Increasing flexibility at the interface, with more flexibile

electronics included

Conformal and close fitting in the majority of the device and

components

All components are fully conformable: “electronic tattoo”

1 2 3 4 5

Com

mer

cial

pro

gres

s

Form factor


Replacing the Silicon IC with cheaper Flexible ICs that do simple functions


And Much More…Printed Batteries

$190 mnin 2029

Hybrid Electronics


‒ Large investment, high risk, high reward for a few

Printing Electronics: examples of strategiesCreate a new product category – replace nothing

Improve somethingReplace whole existing devices

Source: JOLED

‒ Cost reduction ‒ Better performance e.g. flexibility or

light weighting

‒ Trend to become a solution provider: conceive and create complete solutions

Source: Samsung

Source: Notion Systems

Solder Mask: Current process

coating drying film plotting

photo mask develop strip final

cure

Solder Mask: Inkjet process

print & UV-pin

final cure

You saved

Process Steps

5


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• The most comprehensive report on the subject by experts

• Detailed ten year forecasts by device type• Assessment of the winners and case studies• Market analysed by: territory · printed vs

non-printed · flexible vs rigid · organic vs inorganic · materials · components · and more…

“...The comprehensive nature of the report saved us from spending a lot of money on market research. The report was indeed very helpful, and it covered most of the areas of opportunity that my team and I thought existed, and highlighted some other areas that we hadn't considered...“

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opportunities in flexible, printed and hybrid electronics · 2019-10-14 · today, wearable...

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