Roll-2-Roll and Photolithography post-processed with LAser digital technology for FLEXible photovoltaics and wearable displays

Project Information

RoLA-FLEX

Grant agreement ID: 862474

DOI

10.3030/862474

Project closed

EC signature date 23 March 2020

Start date 1 May 2020

End date 31 October 2023

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced materials

Total cost

€ 5 762 745,00

EU contribution

€ 4 705 038,38

Coordinated by

ETHNICON METSOVION POLYTECHNION
Greece

Periodic Reporting for period 2 - RoLA-FLEX (Roll-2-Roll and Photolithography post-processed with LAser digital technology for FLEXible photovoltaics and wearable displays)

Reporting period: 2021-11-01 to 2023-10-31

Summary of the context and overall objectives of the project

RoLA-FLEX project has made a significant contribution to advancing the technological readiness of Organic and Large Area Electronics (OLAE): The project has addressed the main issues currently hindering the wide adoption of OLAE technology in Organic Liquid Crystal Displays (OLCD) and Organic PhotoVoltaics (OPV) by reducing the processing costs, improving device stability and lifetime, and introducing new laser processing techniques to increase manufacturing speed and process yield. In particular, RoLA-FLEX has developed new metal nanoparticle inks, solution processed metal oxides and organic semiconductors and employed laser printing, laser sintering and scribing techniques to demonstrate two TRL5 applications:
1. Smart energy platform based on indoor OPVs: A 12% indoor power conversion efficiency (PCE) was achieved for large-area, encapsulated OPV modules, tailored to seamlessly integrate with a smart energy platform. These fully solution-processed modules, utilizing industrial manufacturing techniques and the late-stage customization technology for laser back-end cell interconnections, were integrated into a demonstrator that showcases OPV's advantages and RoLA-FLEX's achievements. The platform enables autonomous sensor operation down to 200 lux, with two versions developed: one generating 5 mW under 1000 lux, and another providing 10 mW, both capable of wirelessly transmitting temperature, humidity, and light data over several kilometers.
2. Smart watch with an integrated OLCD based on Organic Thin Film Transistors (OTFT): 14” OTFT backplane samples have been laser processed, delivering digitally fabricated OTFT backplane gates and complex Integrated Gate Driver (IGD) circuits. Initial display batches for OTFT/OLCD modules were assembled as demonstrators proving the successful operation of IGD circuits using organic semiconductors developed within the project. Although the current display resolution is 1.5 to 2 times lower than commercial smartwatch displays, further advancement of the laser printing process is expected to to reduce gate line width and enhance OLCD resolution and contrast ratio. The electronics necessary for driving the OTFT/OLCD display have been developed and a non-functional early prototype has been assembled and integrated the final OTFT/OLCD display module.
Regarding the dissemination and exploitation activities, 13 scientific paper publications, and 12 conference presentations have involved the project's results. Monitoring of waste management, IPR development, and data collection for manufacturing cost analysis report were conducted. The Commercialization Roadmap for Application 1 was drafted, comprising OPV market penetration strategy, the associated value chain and the future commercial targets. The Commercialization Roadmap for Application 2 consisted in smart watch and wearable display market penetration strategy, the associated value chain and the future commercial targets.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project progress aligns with objectives and timelines, with justified minor deviations. Key updates in different work packages include:

WP1 (Specifications and end-users’ requirements):
The demonstrator specs have been aligned with the end-users' requirements. Updates on the the specs have been approved by the end-users and confirmed the applicability of RoLA-FLEX's innovations.

WP2 (Organic materials design, synthesis, and upscaling):
Improved polymerization reaction for IDT-BS organic semiconductor polymer in OTFT application.
Substitution of PBDB-Tf-T1 with PUMA donor material in OPV application.
Challenges in PUMA batch performance addressed with process modifications.

WP3 (Inorganic materials synthesis, characterization & scale-up):
Evaluation of metal oxides for inverted structure OPVs.
Successful use of nano Ag and Cu inks with optimized properties.

WP4 (Roll-to-Roll combined with laser digital processing for flexible and ITO-free OPV):
Functional OPV cells achieved on flexible substrates.
Challenges in upscaling materials for Roll-to-Roll coating addressed.
First functioning module developed by TNO, with sintering quality limitations.

WP5 (Photolithography process combined with laser printing and sintering for flexible OTFTs):
Design completion and assembly of OTFT backplane and OLCD frontplane masks.
Evaluation of new ink (H76R) for laser printing process on 14inch panels.
Investigation into optimal laser sintering power for OTFTs validated.

WP6 (Integration, demonstration, and validation of OLAE applications):
Demonstrated 12% PCE for large-area, encapsulated OPV modules.
Smart energy platform demonstrator developed, combining OPV modules with sensors.
Assembly of OLDC into curved BLU and functional demo.

WP7 (Dissemination and exploitation):
Dissemination through the project website, scientific papers, conferences, and webinars.
Completion of a manufacturing cost analysis report.
Commercialization roadmaps drafted for OPV and OTFT applications.

WP8 (Project management and Coordination):
Successful organization of meetings and progress reports.
Project amendments related to specific tasks and deliverables.

WP9 (Ethics Requirements):
Consistent monitoring and assessment of ethics requirements.
No new ethical issues identified.

The project has met its objectives, addressing challenges and making progress across various work packages. Dissemination and management activities are well-coordinated, and ethical considerations have been consistently monitored

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Within the current reporting period, significant progress has been realised in terms of the following Key Performance Indicators:
Use case 1: development of an indium tin oxide (ITO)-free, flexible Organic PhotoVoltaic (OPV) prototype for the powering of a smart energy platform used in IoT environment.
• ITO-free OPVs: the metal grid technology facilitated by laser printing and laser sintering of Ag nanoparticle inks has already demonstrated bottom electrodes with over 80% transparency and over 35000 S/cm conductivity. This electrical performance is by far superior to the ITO counterparts, which show on average 9,500 S/cm.
• Increased PCE: PCEs of 12% for OPV cells and modules have already been measured, and the target of 16% has been reached at the cell level.

Use case 2: OLCD/OTFT display prototypes and their application in wearable smart watches.
• Lightweight & small bezel design: the laser processing of the gate electrode and the laser fabrication of integrated gate drivers enable a lightweight design with minimized bezels, in line with the latest requirements of the wearable displays industry.
• High resolution and brightness in flexible form factors: A resolution of up to 165 x 300 pixels pixels has been achieved and a curved display was integrated to a matching back light unit and polar wrist-band.

The RoLA-FLEX project impact relates to the main issues currently hindering wide adoption of OLAE technology in displays and OPVs by reducing the processing costs, improving device stability and lifetime, and introducing new processing techniques to increase manufacturing speed and process yield.

RoLA-FLEX demos highlights as of M42