Barrier Films for Flexible Electronics: Needs Players & Opportunities

Published by: IDTechEx Ltd

Published: Mar. 1, 2009 - 106 Pages

Table of Contents

1. SCOPE

2. INTRODUCTION TO ENCAPSULATION

3. SURFACE SMOOTHNESS - DEFECTS

3.1. Important considerations of surface smoothness

3.2. Micro Defects

3.2.2. Pinholes

3.2.3. Smoothness / Cracks-Scratches

3.2.4. Nanodefects

4. COMPANIES

4.1. Vitex

4.2. GE

4.3. 3M

4.4. CPI

4.5. Fraunhofer -POLO Alliance

4.6. Alcan Packaging

4.7. Others

4.8. Best performing barriers developed to date

5. BARRIER MEASUREMENTS

5.1. The Calcium test

5.2. MOCON

5.3. Illinois Instruments

5.4. Fluorescent Tracers

5.5. Black Spot Analysis

5.6. Tritium Test

5.7. CEA

5.8. 3M

5.9. IMRE

5.10. Mass Spectrocopy - gas permeation (WVTR & OTR potential applications)

5.11. Standardization efforts

6. FORECASTS FOR BARRIER FILMS FOR FLEXIBLE ELECTRONICS 2009-2019

6.1. The potential significance of organic and printed inorganic electronics

6.2. Forecasts for flexible electronics 2009-2019

6.3. Barrier films market size

7. CONCLUSIONS

8. REFERENCES

APPENDIX 1: ATOMIC LAYER DEPOSITION

APPENDIX 2: GLOSSARY

APPENDIX 3: IDTECHEX PUBLICATIONS

TABLES

2.1. Water vapor and oxygen transmission rates of various materials.

2.2. Requirements of barrier materials

3.1. Oxygen transmission rates of polypropylene with various coatings.4, 7

4.1. Overview of promising high barrier technologies

5.1. Lower detection limits of several barrier performance measurement techniques

5.2. Metrics and standards for organic solar cell components42

6.1. Leading market drivers 2019

6.2. Market value (US$ billion) of flexible/conformal electronics 2009-2029

6.3. Total market value of flexible vs. rigid electronics 2009-2029

6.4. Barrier Layer Market Forecasts 2009-2019

FIGURES

1.1. Examples of flexible OLED displays by SONY and AddVision

1.2. Flexible OLED fabricated using IMRE's high barrier substrate and encapsulation technique44

1.3. Flexible Solar Cell developed by Fraunhofer IPMS

2.1. Schematic diagrams for encapsulated structures a) conventional b) laminated c) deposited in situ4

2.2. Scanning electron micrograph image of a barrier film cross section6

3.1. Visual defects of a selection of materials with barrier films highlighted through calcium corrosion test. Optical microscope magnification 10x.44

3.2. SEM pictures of the Atmospheric Plasma Glow Discharge deposited silica-like films on polymer substrates. Left: Film with embedded dust particles . Right: uniform film27

3.3. OTR as a function of defect density, the correlation between defect density and the oxygen transmission rate

3.4. SEM image of a pinhole defect formed from a dust particle32

3.5. Scanning electron microscope image of ITO coated on parylene/polymer film34

3.6. The measurement of OLED's lifetime of SiON/PC/ITO and SiON/parylene/PC/parylene/ITO substrate34

4.1. Examples of polymer multi-layer (PML) surface planarization a) OLED cathode separator structure b) high aspect ratio test structure.3, 8

4.2. Vitex multilayer deposition process8.

4.3. SEM cross section of Vitex Barix material with four dyads.

4.4. Optical transmission of Vitex Barix coating8.

4.5. Edge seal barrier formation by deposition through shadow masks10.

4.6. Three dimensional barrier structure. Polymer is shown in red, and oxide (barrier) shown in blue10.

4.7. Schematic of flexible OLED with hybrid encapsulation31

4.8. Schematic of cross section of graded barrier coating and complete barrier film structure1.

4.9. DuPont Displays technology pipeline

4.10. Scanning electron micrograph of a thin hybrid polymer coating on SiOx deposited on a flexible PET film 46

4.11. OTR values achieved with different POLO multilayers46

4.12. ALCAN Packaging flexible barrier based on PET and SiOx47

4.13. Specifications on WVTR for different applications, as seen by Vitex Systems36

4.14. 3M specifications on WVTR and OTR for high barrier applications with stringent requirements 14

5.1. 2.25 mm2 area of a 50 nm layer of Ca deposited onto barrier coated PET viewed through the substrate. i. Image after 1632 h of exposure to atmosphere; ii. Image analysis whereby the grey scale of Ca degradation is processed to yield a two-color image with

5.2. A simple set-up for measuring optical transmission of calcium test cells48

5.3. MOCON's Aquatran™ Model 138

5.4. MOCON's Aquatran™ schematic38

5.5. MOCON's OX-TRAN® Model 2/1039

5.6. Silica induced black spots, letters A & B mark black spots with a centralized black dot (silica particle)32

5.7. Black spot formation and growth mechanisms 32

5.8. General Atomics HTO WVTR testing apparatus40

6.1. Market value (US$ billion) of flexible/conformal electronics 2009-2019

6.2. Total market value of flexible vs. rigid electronics 2009-2019

6.3. Barrier Layer Market Forecasts 2009-2019

6.4. Size of opportunity

7.1. The iRex iLiad and the Amazon Kindle rigid e-book readers

7.2. PVI's flexible electrophoretic display and color electrophoretic display by SAMSUNG LCD, demonstrated at SID 2008

Abstract

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