MSE 542 Flexible Electronics - Erdinç Kuruoğlu...Smart Biomedical Bandages Temperature Sensors...
Transcript of MSE 542 Flexible Electronics - Erdinç Kuruoğlu...Smart Biomedical Bandages Temperature Sensors...
MSE 542Flexible Electronics
Lecture 1
Tuesdays, 1:25 pm to 4:30 pm
Olin 245
Example 1:Flexible Displays
• Flexibility enables new concepts in electronics
Smart Biomedical Bandages
Temperature Sensors
AntennaControl Electronics
and RFID
Battery
Fluid SensorsGas Sensors
Example 2:Smart Bandage
Simple processes enable low cost
What is Flexible Electronics?
• Flexible electronics “can be bent, flexed, conformed or rolled to a radius of curvature of a few centimeters without losing functionality”
• Thin profile
• Large area
• Conformal
• Flexible
• Wearable?
• Possibly manufactured roll-to-roll
Course Description• Flexible electronics holds the promise of transformative
developments in: (1) flat panel lighting (low cost, low energy), (2) energy production systems (solar) and (3) infrastructure control and monitoring (sensing, energy control, hazard monitoring).
• Practical realization of flexible circuits will require dramatic progress in new materials that are compatible with flexible media and amenable to facile and low temperature processing as well as major advances in manufacturing technologies such as roll-to-roll processing.
• This course will discuss these and other developments.
• Lecturers will come from Cornell, GE, IBM, EIT, Binghamton
Technology Convergence Makes Flex Possible
• Thin film transistors
• Active matrix
• Conducting layers
• Plastic, glass and metal substrates
• Barrier layers
• New deposition methods
Why is This Topic so Exciting?
• Flexible electronics, if low cost enough, means that we can give electronic attributes to everyday objects
• Imagine displays that roll up and fit in your pocket
• Imagine solar panels are your clothes or the fabric is a sensor net
• Imagine light sources you hang like a picture on a wall
Examples
• Flexible Displays
• Flat Panel Lighting
• Solar Cells
• RFID Tags
• Smart Bandage
Pioneer e-Ink & Lucent Electrolux
Electronics go everywhere
Sony eReader
RFID
• Imagine a carton of milk with RFID tag
• Refrigerator will tell you when it is out of date or used up
• Will be used to track inventory of most retail items
• Where will it end up?
Alien Technology
Pioneer(2001 - demo)Pioneer
(1997)
Motorola(2001)
Kodak(2004)
Sony(2004)
Organic light emitting diodes (OLEDs)
OLEDs vs. Liquid Crystals
GE
OLEDs for lighting
Electrolux
All-polymer integrated circuits (Philips, 1998).
Organic thin film transistors (OTFTs)
SustainableTechnologiesInternational
Solaronix
OPVs Solar Cells for energy production
Class Expectations• There will be problem sets
approximately every two weeks.
• There will be a class prelim.
• There is NO FINAL, but there is a term paper due during study week. – The topic will be selected in conjunction
with the course instructor.
• 30% Homework
• 30% Prelim
• 40% Final Term Paper
Seminar Series
• We will hold a separate seminar series starting mid-way through the semester
• Distinguished speakers are leaders of the developing flexible electronics community coming from industry and academia
• Attendance at seminars will be greatly encouraged, but is optional
Texts• Flexible Flat Panel Displays (Wiley Series in
Display Technology) (Hardcover)– by Gregory Crawford (Editor) – Hardcover: 556 pages– Publisher: John Wiley & Sons (June 21, 2005) – ISBN: 0470870486
• Principles of Electronic Packaging – by Donald Seraphim, et al.– Hardcover: 962 pages– Publisher: McGraw-Hill College (March 1, 1989)– ISBN: 0070563063
Silicon Run Video
• This video shows where flexible electronics comes from, factors to consider
• It is important to see what flexible electronics is evolving from and to understand that today these are not yet competitive areas
• Not as small, not as fast, but enabling new uses and concepts to be realized
Break & Discussion• What did video show?
• Showed chip processing - now we need to consider “packaging”
• Adjustments to get higher performance
• Used to be considered less important, but now package is bottleneck in many electronics if not done right
• Advances in packaging are basis of new flexible electronics!
Other Ideas?
• environmental sensors
• make inanimate devices active - e.g. furniture, rooms, etc.
• tag everything - passports
• biomedical implants - connect the nervous system to the external world
What skills do we need?
• Flexible electronics can be thought of as combination of microelectronics (albeit on larger scale) with electronic packaging
• Need understanding of materials and electronics
• It is a new and developing area
• As such we will look at this from perspective of both these areas
• Most of all we need imagination!
What makes flexible different from current microelectronics?
• Thin form enables flexibility, BUT places additional demands on mechanical performance
• Normal protective packaging is too big, so new methods of protection are needed
• Speed is not essential
• New methods of manufacture may enable cost reduction, but compromise robustness
Course InstructorsProf. C. K. Ober, Cornell lead
• Dr. Poliks, EI lead
• Prof. Baker
• Prof. Giannelis
• Prof. Malliaras
• Prof. Thompson
• Prof. Sammakia, BU
• Dr. Obrzut, NIST
Dr. Calmidi, EI
Dr. Chan, EI
Dr. Egitto, EI
Dr. Fillion, GE
Dr. Korman, GE
Dr. Magnuson, EI
Dr. Matienzo, EI
Dr. Wilcox, IBM
" Over 40 Years experience in development and fabrication of leading edge technology
" Incorporated as Endicott Interconnect in November 2002
" A tradition of technical invention
" Facility - 1.3M sq feet manufacturing and lab space
" EmploymentFabricationEngineeringResearch & Development
" Prototyping through volume production in three shift operation
EI Corporate Profile
Class Outline
Jan. 24 Course overview: What is Flexible Electronics? (Ober)
Jan. 31 Design: Connectors and interconnects (Chan, EI; Wilcox, IBM)
Feb. 7 Technology Focus: Displays and lighting (OLEDs) (Malliaras)
Feb. 14 Performance: Electrical performance and characteristics (Obrzut, NIST)
Class OutlineFeb. 21 Design: Single and multichip packages
(Fillion, GE)
Feb. 28 Processing: Lithography and pattering (Ober)
March 7 Processing: Laser processing and via formation (Egitto, EI)
March 14 Design: Substrates and barriers (Poliks, EI; Giannelis)
March 28 The Flexics Story - History of a Startup (Thompson; Wickboldt, USDC)
Class OutlineApril 4 Technology Focus: Solar energy
conversion (Korman, GE)
April 11 Processing: Metal deposition (Baker; Magnuson, EI)
April 18 Performance: Physical Analysis (Matienzo, EI)
April 25 Design: Future technologies (Chan and Lin, EI)
May 2 Design: Thermal management and reliability; Course Wrap-up (Calmidi, EI; Sammakia, BU; Ober)
Or What Do Electronic Devices Need To Do?
• Chip/Circuit Protection
– Environmental, thermal, mechanical
• Communication
– Maximize I/O
• Power• Heat removal
- Forced or natural convection
- Wiring structure and power interconnects
What Is Packaging?
• Rivals microelectronics in terms of industry size and complexity
• Critical bottleneck in device speed
• Sets size and capability of electronic device
• Determines cost of device
Packaging vs. Microelectronics
The Package
Each level needs to meet goals of package!
• 1st Level – chip on substrate
• 2nd Level – card
• 3rd Level – card on board
– packaging getting as sophisticated as microcircuit
– how will we categorize package for flex?
Levels of Packaging
Packaging Technologies
New Technologies Needed for Flex
• Materials selection
• Circuits on substrate
• Processing conditions and limits
Conductors
Fewer conductors to choose from
Insulators
Largely organics
2nd-Level Packages(How would they function for flex?)
Single Chip Packages
• Die attach
• Wire bonding & Plating
• Encapsulation - molding compound
• Package types
• Quad flat pack
• PLCC
• PGA
• BGA
• C4
Chip Package
• Combine several chips in one package
• Reduces signal delay time
• Heat dissipation
• Stress relief
• Substrate is high signal density layer
TypesMCM-LMCM-CTCM
Multichip Modules
• Attach chip to plastic carrier with metallization
• Looks like 35 mm film
• Speeds up production
• Usually polyimide & copper
• Flex circuits use similar technology
Tape Automated Bonding (TAB)
• Composite - often epoxy/glass
• Parallel process
• Screen printing
• Lamination
• Multilayer crossed by vias
• Capacitance, inductance and resistance
• Pick and place
• Solder & reflow
• Thermal issues
PCB or PWB
• Maximize I/O
• Minimize thermal issues
• Heat dissipation
• Thermal stress
• Environmental protection and encapsulation
• Lowest cost needed to get results
• Drive to continuously reduce size and power
Common Themes(Flex will have to achieve this)
Endicott
Interconnect
Microelectronics Advanced Interconnections
Laser via / thin film / z-interconnect based interconnect technology needed to reduce the IC to PWB interconnect gap
HyperBGA is a registered trademark of Endicott Interconnect Technologies, Inc.
Semiconductors versus PackageSmallest features: “parallel paths” for how long?
IC scaling
Time
PWB
PWB w/ buildup layers& Laser vias
Reduced Interconnect
Gap
HyperBGA® Interconnect technology
2000’s1990’s 2010’s
Z-interconnect technology
Meso
Micro
Nano
InterconnectGap
$SOP
Source: adapted after
Shipley
© 2005 Endicott Interconnect Technologies, Inc.
Endicott
Interconnect
Time 2015-202000-5
2005-10 2010-15
Func
tion
-- D
ensi
ty
Data Rate Gb s-15 20 10 40
Embedded Actives
Electrical Interconnect
Optical Interconnect
Embedded Passives
Integrated Systems Technology Evolution
Organic z-interconnect
IntegratedFlex, Optical, Passives & Actives
Enhanced Thermal and Power Management
IntegratedOptical, Passives
HyperBGA
Integrated RF
Flexible Substrates
© 2005 Endicott Interconnect Technologies, Inc.
• Flexible substrates
• Barrier layers
• Inorganic conducting layers and mechanical properties
• Organic conducting layers and mechanical properties
• Optical coatings
• Thin film transistors
• Electro-optic materials
Flexible Electronics:Enabling Materials
• Patterning Methods
• Printed organic electronics
• Rollable materials
• All plastic systems
Enabling Processes
• Flexibility creates potential problems as the multilayer film is flexed
• Different E
• Different CTE
Flexibility
Stress Cracking
Modulus mismatch leads to stress cracking
Mechanical Properties of Layer Components
MaterialYoung’s modulus,
E (GPa)
Coefficient of Thermal
Expansion, CTE (ppm/K)
Hardcoat 6.0 ± 0.5 61 ± 1
Base polymer 2.9 ~65
Gas Barrier 150 10
ITO 119 ± 5 7.6
Organic Substrates
Flexible plastics are not as thermally stable as glass or metal
New Semiconductors
Polymers can be used a semiconductors and even doped to be conductors
TFT’s
• TFT’s on flexible substrates can be produced from polymeric or inorganic semiconductors using printing methods
• Barrier layers are needed to protect the various components from the environment
Barrier Layers
• New processing is enabled by new materials
New Patterning Methods
Future Prospects
• Future applications not even imagined do not appear here
The U.S. Early Adopter for Flexible Displays
The Air Force has announced a complementary program using OLED on SSSource: John Pellegrino (ARL) and Darrel Hopper (AFRL)
UNIVERSITIES
GOVERNMENTLABS/RDECs
INDUSTRY
Technology into Center
Technology subsetsfrom the Center (i.e. backplanes)
Limited Quantitiesof
Display Demos
Flexible Display Center @ ASU
United States Army
Flexible Display Centerof Excellence
Roll-to-Roll Manufacturing R&DMotivation and Purpose
A proposed means to lower the cost of producing flexible displays in a high-volume manufacturing
environment by taking advantage of a unique attribute of flexible substrates relative to the traditional thick
glass substrate used in LC displays.
Such a manufacturing paradigm, compared to the traditional batch process (cluster tools and cassette transport), generally does not enable any enhanced
product performance characteristics.
What is Roll-to-Roll (R2R)?
• Substrate is a Flexible format
• L>>W>>T
• Can be stored in coils (D<1m)
• Handled in Rolls:
Unwind – process - Windup
T
W
L
SteelPlastics
D“Web”
Converging interests from other developing industries
Opportunity: pool resources and knowledge
Large Area
Solid State Lighting• Low cost production of OLED
panels
Thin Film Photovoltaics•Reduce cost
•Improve yield
Flex Circuit Packaging•Reduce L/S < 15um
•Embedded actives, passives
•Integrated passives, active
Low Cost RFID•New TFT technologies
High precision R2R electronics
manufacturing
Challenges & Opportunities for R2R• Engineering
– Need to develop R2R equipment to operate at IC-industry specifications
Existing hurdles:
– Damage due to handling
– Particle generation
– Impurity due to contact
– Yield management
– Linear processing
• Financial
– A fully integrated facility
– Lower capital cost
– Lower labor costs
Because it may be essential to enable the high volume applications of flexible electronic products and systems and it is highly compatible with organic electronics & solution processing!
• Flexible
• Formable
• Weight
• Ruggedness
• Low Cost
• Many customers will not pay a premium for these.
• However, a premium is inevitable for new
technology.
• Customers have come to expect lower cost!
Roll-to-Roll Production?
Why R2R Manufacturing?
Roll-to-Roll ManufacturingWhat it is NOT in the context of the FDI!
• Not an essential capability to produce flexible displays
• Does not satisfy a gating Army need (volume, application variability)
• Not a near term capability (either from an ability to accomplish or a market demand point of view)
• Does not meet the Army timeline
• Not appropriate for a display technology development environment
USDC CONCLUSIONS & GUIDANCERoll-2-Roll Manufacturing – A Companion Initiative
• Supporting Factors– There is insufficient funding in the Army program to do both initiatives ►spend the “marginal” funding on the important and essential display component deliverables at the FDC
– Keep the ASU team focused on displays and backplanes to meet the Army’s objectives for the FDC
– Core competencies very different for addressing flexible displays and R-2-R manufacturing technology ►different industries [tool & process development expertise] and very different academic R&D expertise
– Commission someone else with the responsibility to secure additional funding and support• Other funding avenues, e.g., state, federal, industry
• Industry partners from outside the display community
– Efforts can run more concurrently [although not essential to meeting Army flexible display objectives] without dissipating focus and funding
New effort in U.S.: CAMM (Center for Advanced Microelectronics Manufacturing)
• Located at Binghamton University (New York State)
• Launched in January 2005• Develop and demonstrate
advanced integrated R2R manufacture of microelectronics
• Test site for USDC R2R projects• Facilities provided by Endicott
Interconnect TechnologiesSigning Ceremony Jan’05
If there is interest, we can visit!!