the old bishop™s almanac · light emitting polymer (lep) -50nm polymer transport layer - 50nm top...
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© C.A.Bishop Consulting Ltd 2005
CONSULTING LTD
The Old BishopThe Old Bishop’’s Almanacs Almanac
Prognostications for the Prognostications for the future of Vacuum Coatingfuture of Vacuum Coating
2005
This is my view of the industryThis is my view of the industry
These may NOT represent the views of AIMCAL
If
you disagree & think I am wrong
shout out & let us know why
Agenda• Barrier – the measurement con
• Indium – ie ITO for Displays
• The overseas threat/opportunity
• Slitting – the myth
• Cleanliness – gap analysis
• Low cost machines
Super Barrier-
the measurement
CON
Barrier – the measurement con
Claims of barrier coatings of 10-6 g/m2/day
BUT calibration stops at 5 x 10-4 g/m2/day
Many coatings have a value taken before they reach steady state conditions – which (surprise, surprise) are worse!
Barrier – the measurement con
Time
truediffusion
performance
Barr
ier
per
form
an
ce
-L
og –
g/s
q m
/da
y
1 dyad more dyads bigger time lag
hours days
Barrier – the measurement con
polymer (sponge)
transparent oxide coatings
oxide/polymer pair = 1 dyadpolymer (sponge)
1st polymer = smoothing layer
substrate
moisture in atmospherediffusing into substrate
moisture that has diffusedvia a tortuous path throughwhole structure of 5 dyads
AnyAnyQuestionsQuestions
ororComments?Comments?
Audience participation
A show of hands please
Who thinks of China as a threat?
Who thinks of China a an opportunity?
I am about to double your worries!
Your options might be better than you think
The overseas threat/opportunity?
• China– Economy + 9.5% growth
– + 15 yrs growth ~<5.0%
– 10-20 yrs 2nd largest
– Business needs part Chinese ownership
– Economy stability ???s
– Hourly rate ~ $0.67
• India– Economy + 8.0% growth
– 10yrs >growth than China
– 10-20 yrs 3rd largest
– Less business constraints greater % investment allowed
– More stable economy
– Hourly rate ~ $0.58
– Educated + English speaking
AnyAnyQuestionsQuestions
ororComments?Comments?
Indium
(revisited)
Indium – ie ITO for Displays?
Nostalgia Nostalgia –– Here is what I said last yearHere is what I said last year
Indium – by product of mining zinc
Zinc price low – falling – mines closing
Indium price increasing
Indium requirement increasing
Indium price will increase further
Indium
• Indium – mined as a by-product of Zinc
• Indium – less than 400 tons mined per year
• Zinc – Mined as primary product
• Zinc – ~ 9 million tons mined each year
• Zinc – price at an all time low
• Zinc – mines being taken out of production• Some on economic grounds &
others because of problems
Indium
0
200
400
600
800
1000
1999 2000 2001 2002 2003 2004 2005
Price $/kg US use Tons World Prodn Tons
IndiumThis is worse than it first appears
Indium – less than 400 tons mined per year
400 Tons of unrefined ore
~ 8 – 8.5 tons of ore = 1 ton refined metal
By 2006 LCD industry will need ~ 64 tons
***** 64 x 8.25 = 528 Tons *****
Indium
Buy now
to
avoid
disappointment
Alternatives?
• e.g. Aluminium doped Zinc Oxide
• Or others (Fluorine doped Tin Oxide)
• If you want to play – start now – (too late?)• (Threat from conducting polymers cf HP LCD’s)
AnyAnyQuestionsQuestions
ororComments?Comments?
Slitting – the myth
Slitting
Who has seen film edges like this?
or
substrate
RaisedHairyJagged
Slitting
with a poorly slit edge as the web is wound up in vacuumthere is no entrapped air to hide the problem & the edgegrows much higher than the rest of the webuntil the raised edge folds over
substrate
Final roll has the shape of a ‘dog-bone’
Slitting
Would it surprise you to know
In a variety of other industries that used mechanical (blades) for cutting they have all eventually progressed to laser cutting
Slitting
• The progression
• Blades
• Blades – harder materials
• Water jets
• Gas/plasma torches
• Lasers
(e.g. see steels & fabrics)
Slitting
• Q. Why do polymer films still get slit by blades?
• Advantages of laser slitting• Cleaner cut – no raised edges
• Cleaner cut – less debris added to web
• No blades to re-sharpen
• Easier resetting to new widths
• A. Dogma – - cost? + don’t have to until somebody else does – - - - no customer pressure
AnyAnyQuestionsQuestions
ororComments?Comments?
Cleanliness-
Gap analysis
substrate
ITO ~~ 200nm
Light Emitting Polymer (LEP) - 50nm
Polymer transport layer - 50nm
Top metal electrode
Light output
Total coating thickness <0.5 microns~ same dimension as residual debris after cleaning
0.3microns
dia
Organic light emitting display (OLED)
barriercoating
Leak throughpinhole
Both sides barrier coated. Pinholesare rarely in line & hence one layer or the other provides the barrier.
Barrier performance
Pinholes
substrate
metallization
debris
Pinhole
Debris typically >0.5 microns
metallized layer 20 – 100nm
Debris diameter in microns
Numberofdefects
Particle count
82100Polycarbonate (cast)
400 – 50023Melinex co-ex ‘B’
Not the worst tested2500 - 300023ANO
40023Mylar D
Average 1-2microns125 - 15023Melinex co-ex ‘A’
45 – 30075Melinex ‘O’ knurled
Both sides same3575Upilex
550 – 65075Mylar D
65075SKC
CommentsDefect Count
Average of 6 fields
ThicknessFilm Type
NB After slitting the defect count was, on average, 2x greater
Surface defects
cooled deposition drum cooled deposition drum
thermal expansion substrate
thermal load thermal load
As the heat load is applied the substrate wants to expand but is constrained by the friction between the substrate and cooled deposition drum
Now there is some debris preventing the web laying flat on the surface of the drum. There is then, locally, less cooling & the web wants to expand. As it is already off the surface this is easy to achieve & the wrinkle starts.
Effect of debris
Debris
Keep the drum & substrate clean
polymer webextruder
castingdrum
forwarddraw
sidewaysdraw ovens
edgetrim
rewindrolls
Areas where dust/debris can be generated or come in contact with web on a polymer web production process.
Cleanliness – Gap analysisClean
Dirty
Stateof
filmmakingsystem
Day 1 Time
accumulation of debris
in & around machine
customer requirements
AnyAnyQuestionsQuestions
ororComments?Comments?
Low cost vacuum systemsLow cost vacuum systems
Where do we start?
Lets start with a chamber
Low cost vacuum systems
The chamber
What material?
Mild steel – stainless steel - ???
Q. Why not plastic?• Engineering plastics – lightweight – easily machined
• Cylinder shape & compression loads
• Finite Element Analysis – check designs - safety
Q. Benefits from more radical thinking?
Drives
Chamber using thick-walledpolymer pipe
~ 600mm dia for 300mm roll width
Inner rigid frame for accurate winding system
pumps
AnyAnyQuestionsQuestions
ororComments?Comments?
where are we now? where are we now?
Flexible OLEDsFlexible OLEDs--
NanotechnologyNanotechnology
Gartner hype cyclefor emerging technologies
Technology Peak of Trough of Slope of Plateau of Trigger Inflated Disillusionment Enlightenment Productivity
Expectations
Visibility
Maturity
ObsolescenceObsolescence
ObsolescenceHow many of you have machines over 10yrs old?
When you buy a new machine do you –
want the newest technology?
want computer control?
expect it to still be working in 10yrs?
Have you considered -- if anything goes wrong you may not be able to get things repaired because of obsolescence of components?
Warning
Many long term systems now have a problem with electrical components becoming obsolescent.
The speed of development & change now means that in 10yrs several generations of ‘improvements’ may have occurred & the new versions will no longer work in outdated systems.
© C.A.Bishop Consulting Ltd 2005
Good luck Good luck
&&
See you next yearSee you next year
CONSULTING LTD
Thank you.Thank you.
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