fantastic plastic

Konarka (organic photovoltaics) and Toppan Forms (Data Print Services and information management services)

have signed a joint agreement to accelerate the development, manufacturing and commercialization of polymer-based organic photovoltaic (OPV) technologies for consumer and electronic applications. Under the agreement, the mutual goal is to bring Konarka’a organic photovoltaic material, Power Plastic®, to market.

“Konarka’s Power Plastic is flexible, thin, printable and low in cost, providing our organization with promising new business opportunities as we strive to become an integrated information management service company,” commented Masanori Akiyama, president and CEO of Toppan Forms. “With the full-fledged advent of the ubiquitous society under way, we need an ever-present power technology that can be integrated with pervasive networked devices for information collection and distribution. We are delighted to collaborate with Konarka, the world leader in OPV technologies, to accelerate the commercialization of this transformational power technology to the market place.” […]

“The partnership with Toppan Forms represents a key milestone for the commercialization of Power Plastic,” commented Rick Hess, president and CEO of Konarka. “This relationship enables each company to focus its expertise and resources on key product development processes, continuing our go-to-market strategy of partnering with leading global companies for a variety of applications.”

According to DigiTimes, Chi Mei EL Corporation (CMEL), a Chi Mei Optoelectronics (CMO) subsidiary,

started [to] volume produce active-matrix (AM) OLED (organic light-emitting diode) panels in May, with monthly capacity able to reach 500,000 2-inch equivalent panels at present.
Zhe-yang Chen, president of CMEL, said the company has begun shipping 2-inch AM OLED panels to China- and Japan-based customers and end products adopting CMEL’s panels will hit the market in July at soonest. […]
The company now sees related yields at 60%, which will be improved to 80% by year-end, said Chen. Achieving high yields in the AM OLED industry is not easy; even leading makers such as Samsung SDI only targets yields at 60-70% initially, he pointed out. […]
Prices for an AM OLED panels now are still 1.8 times higher than those for the same-size TFT LCD panels. The company expects to see the price gap between the two segments narrow to 1.5 times in the future, according to Chen.

Polymer Vision (Eindhoven, NL) has announced its cooperation with Innos (Southampton, UK) to manufacture rollable displays:

Following 10 years of research, Polymer Vision has spent the past three years processing displays in its own pilot facility in Eindhoven to develop the technology to maturity. Polymer Vision and Innos will together transfer the process technology and finalise qualifications in Southampton, UK, where Innos has already started installing equipment in its newly built cleanroom. In line with their strategy to use mainstream Thin Film Transistor (TFT) equipment, Polymer Vision is confident that they will rapidly scale up to commercial volumes in 2007.

According to CNET, Cyberlux are developing white LEDs combining an inorganic semiconductor with an organic phosphorescent layer:

In conventional white-light LEDs, a semiconductor emits blue light. The blue light passes through the phosphor and becomes white light. The phosphor is thin film on a substrate; the substrate has to be placed in intricate proximity to the semiconductor. Positioning the phosphor is one of the more expensive steps in creating an LED, Schmidt said.
In the coming prototype, the conventional phosphor is replaced with a sheet of polymer, which sort of applies itself to the LED, almost like a layer of shrink wrap. The technology was invented by UC Santa Barbara’s Steven DenBaars, who has been a big advocate of LED lighting as a way to increase energy efficiency and reduce greenhouse gases, and Nobel Prize winner Alan Heeger. Heeger also helped found solar-technology company Konarka Technologies.

According to their press release, MicroEmissive Displays (MED, Edinburgh, UK)

will start commissioning and qualification of its new production plant in the Fraunhofer IPMS in Dresden early in 2007. The move comes following the on-time handover of the purpose built cleanroom and delivery of the tool set from ANS Korea.

The 350 m² purpose built cleanroom is state of the art and is located within the substantial facilities of the Fraunhofer IPMS campus. Construction of the cleanroom was completed on time; equipment is in place and installation is already underway. The tool set, delivered from ANS Korea in December, comprises polymer OLED based deposition and thin film
encapsulation equipment for mass production.

At the same time MED has announced that

it has received a £2m order for its new polymer-OLED eyescreen™ microdisplay. The order, from a manufacturer of consumer products in the Far East, will also be the first to ship from the company’s new manufacturing facility in Dresden.

The order relates to MED’s new eyescreen™ ME3204 microdisplay. The new device is a compact 6 mm (0.24”) colour P-OLED QVGA display. The P-OLED technology is emissive and so does not require a backlight; as a result eyescreen™ ME3204 is ideal for portable applications such as video glasses or head-mounted displays, electronic view finders and night vision systems. The microdisplay can be combined with magnifying optics to produce a large virtual image that appears to the eye to be equivalent in dimensions to the picture on a TV screen or computer display.

In addition eyescreenâ„¢ ME3204 features a digital video interface together with an integrated display driver eliminating the need for additional driver ICs. This design feature saves space and reduces both power consumption and BoM costs.

OTB Display announced

that it is able to produce thin film encapsulated OLED devices that meet the shelf-life requirements for commercial use. Not only are these displays manufactured on OTB’s in-line mass manufacturing equipment, but also the deposition of the thin film encapsulation has been proven to render the same optical performance as the conventional, more expensive glass-can encapsulated devices. […]
Bas van Rens, CEO of OTB Display, explains: “Our integrated in-line mass manufacturing equipment now routinely produces displays which pass the accelerated shelf life of 504 hrs at 60oC / 90% humidity. In our development program we observe rapid progress and we expect to be able to announce shelf lifes exceeding 1000 hours at 85 oC/ 85% this year”

Plastic Logic announced that it has raised $100 million to build a factory for flexible active matrix display modules in Dresden (Germany).

To fund this comprehensive commercialization program, Plastic Logic has completed a first closing of $100 million of equity finance led by Oak Investment Partners and Tudor Investment Corporation. Existing investors Amadeus, which led the seed financing of Plastic Logic, Intel Capital, Bank of America, BASF Venture Capital, Quest for Growth and Merifin Capital also participated. The financing is one of the largest in the history of European venture capital. […]
The facility will produce display modules for portable electronic reader devices – a product category that is predicted to grow to 41.6 million units in 2010. It will have an initial capacity of more than a million display modules per year and production will start in 2008. Dresden in the ‘Silicon Saxony’ region of eastern Germany has been chosen as the facility location following an extensive worldwide site selection process.

George Malliaras and coworkers at Cornell created a novel type of organic diode with an “ionic junction” by laminating together layers of

an anthracene derivative containing free positive ions and a ruthenium, complex containing negative ions. When the two are joined, ions diffuse across the junction creating a difference in energy levels that facilitates rectification, electroluminiscence and photovoltaic response.

The technique is potentially suitable for low-cost fabrication of flexible photovoltaics and LEDs.

The work is described in the Sept. 7 issue of the journal Science in a paper by Cornell graduate researchers Daniel Bernards and Samuel Flores-Torres, Héctor Abruña, the E. M. Chamot Professor of Chemistry and Chemical Biology at Cornell, and Malliaras.

ORFID Corporation […] has signed an agreement with BASF Future Business GmbH (BFB), a subsidiary of BASF Aktiengesellschaft, to collaborate on the development and commercialization of printable organic electronic devices for use in display backplanes, RFID tags and other next generation electronic products.
Under the agreement, BFB will provide organic materials, materials expertise and financial resources for the development and commercialization of printable electronics. ORFID will build certain organic devices and develop processes for printing and testing the devices.

ORFID’s technology is based on research by Prof. Yang Yang’s group at UCLA: using a Vertical Organic Field Effect Transistor (VOFET) structure allows ORFID to fabricate TFTs with very short channel lengths (and thus high on-currents), without the need for high-resolution patterning methods.

ORFID has developed a breakthrough in organic electronics, called the VOFET (Vertical Organic Field Effect Transistor). Due to its unique architecture and use of conductive polymers (plastics that conduct electricity) in its fabrication, the VOFET offers performance characteristics similar to conventional, wafer-based silicon transistors, but can be produced at significantly lower cost, while offering other important advantages. Using organic materials, the VOFET can be manufactured using low-cost printing techniques. ORFID’s goal, and that of electronics manufacturers around the world, is to enable the production of a new generation of ultra-thin, light-weight and flexible electronic products, such as displays and “smart packaging” that incorporates printed RFID tags.

[press release]

Cambridge Display Technology (CDT) and Toppan Printing

have produced a number of 5.5 inch full color active matrix polymer OLED (P-OLED) displays using a roll printing method. A demonstrator will be shown at the SID conference in San Francisco. The displays - believed to be the first of their type ever produced - are the result of close co-operation between the two companies and part of their joint development activity announced in February 2005.

Solution processing of P-OLED displays is more commonly associated with inkjet printing, and the companies believe that roll printing represents a promising alternative production technique which offers the potential for very good display uniformity, very high display resolution and low capital and operating costs. […]

The technique is based on relief printing, a well-established method for the transfer of soluble materials onto a range of substrates, but which has been developed by Toppan into a highly precise technology capable of producing patterned pixels of small size and highly uniform distribution. The companies believe that the process is capable of scaling to large substrate size and very high resolution, potentially over 200 ppi.

press release

According to Displaybank

Japans’ Tohoku Pioneer has launched mass production at its new plant dedicating to producing white organic light-emitting diodes (OLEDs) for mobile handset backlights (BLUs), the Nihon Keizai Shimbun reports. The company is first to start mass production of white OLEDs in Japan. With this launch, the OLED plans to ship white OLEDs from the plant in Aomori Prefecture to overseas mobile phone vendors this month.

According to their press release

Toppan Printing Co., Ltd. has developed an amorphous oxide semiconductor thin film transistor (TFT) array and succeeded in driving an electrophoretic E Ink front panel laminate to fabricate a prototype flexible electronic paper display.

Apparently the amorphous InGaZnO semiconductor used here has a higher charge carrier mobility (> 5cm^2/Vs) than a-Si and can be deposited at room temperature. Flexible TFTs based on a-InGaZnO were first demonstrated by Professor Hosono and coworkers at Tokyo Institute of Technology (Nomura et al, Nature 432, 488 (2004)).
All layers of the 2 inch diagonal (80 x 60 pixels) display were deposited onto the flexible PEN substrate by sputtering, but Toppan plans to deposit and pattern some of the layers by printing.

Toppan plans to develop flexible TFTs with goals to commercialize thin, lightweight and flexible displays such as electronic paper, starting with a practical prototype display in fiscal 2008. In parallel, we aim to introduce printing methods into the fabrication process of flexible TFTs for simplification and cost reduction.

Note: This research was reported at IDW’05 as EP2-4L (International Display Workshop, Dec.6-9, 2005, Takamatsu, Japan)

Kyosemi Corporation is developing solar cells consisting of 1mm spheres on a flexible substrate.
More information on the Sphelar solar cells: production process, main features, overview (PDF):

In mid-2006, Kyosemi Corp. plans to begin full-scale mass production of its Sphelar spherical micro solar cell at its Eniwa Operation in Eniwa City, Hokkaido, Japan.
While existing planar solar cells can take light only from their elevation surface, the Sphelar cell allows light to reach its cells from all directions because it has a spherical surface, providing a high level of photoelectric conversion efficiency. […]
The company uses conditions of microgravity to form the Sphelar cells from molten silicon. Surface tension causes the silicon to take on a nearly perfect spherical shape. Due to segregation effects gained during the solidification process, single crystal silicon with a purity of 99.9999 percent can be obtained. The pn junctions are created using an n-plus diffusion process. Silver paste is used to attach electrodes. The product is finished with a coat of reflection film. […]
If a Sphelar cell is encapsulated in acrylic resin, it can be turned into Flexible Sphelar sheet, a thin solar cell module whose shape can flexibly be changed into, say, a crescent or a curved form.
A module made with a series of Sphelar cells connected in parallel on silicone resin achieves a photo electric conversion efficiency of 19 percent.

See also this earlier article (”Spherical Solar Cells Solve Issue of 3-D Sunlight Reception”, 2003).

MicroEmissive Displays (MED) developer of polymer organic light-emitting (P-OLED) based microdisplays have announced the shipment of its first product:

The Company has now shipped the first batch of a multiunit order for distribution into Asia. This first fulfilment is confirmation of the improvement in manufacturing yield, which had previously prevented the Company achieving efficient mass production manufacturing.

MED’s proprietary enabling technology is the first example of silicon and an organic substance working together and is used to produce high-resolution images with low power requirement on microdisplays, making the product ideal for ‘near to eye’ mobile technologies.

This first order will see the displays used in ‘night scopes’ for the leisure and sports markets and the Company expects this to be a key area in the initial stages of the commercialisation of the product.
The Company also sees opportunity in the near to eye mobile entertainment and communication handset markets going forward.