U l t r a - B a r r i e r F i l m s : S c a l e U p o f R o l l t o R o l l P r o d u c t i o n R a v i P r a s a d , C T O V i t r i f l e x B A S I D M a r c h 2 0 1 6 V i t r i f l e x , I n c . , 2 3 5 0 Z a n k e r R o a d , S a n J o s e , C A 9 5 1 3 1 - 1 1 1 5
Overview Flexible, Transparent, Ultra-Barrier Film Products • A Novel Solution for Encapsulation of Flexible Electronics • Enabling the Next Wave of Large-Area Electronic Products DISPLAYS Flexible OLED Display Quantum Dot Films SOLAR PV LIGHTING Flexible Modules Novel OLED Sources Building Integrated Novel Luminaires (BIPV) 2
Barrier Film Applications QD Films Flexible OLED Display Flexible OLED Lighting Flexible Solar PV 3
Market Requirements Requirements for Transparent Barriers Rechargeable Current area of focus for Vitriflex Batteries Organic PV Reflective Displays Electrophoretic OLED Display AMLCD – Packaging OLED Lighting Quantum Dots Inorganic PV • Low WVTR ( Water Vapor Transmission Rate ) – The key parameter [g/(m 2 day)] • High Optical Transmissivity – Low absorption & haze at wavelengths of interest • Mechanical Robustness – Resistance to impact, scratching, soiling, etc. • UV Stability – For outdoor applications like solar • Cost Effective – Roll-to-Roll Processing The goal is a flexible polymer film with glass-like properties 4
Key Benefits Of Polymer Encapsulation UNBREAKABLE FLEXIBLE THIN TRANSPARENT LIGHTWEIGHT 5
The Product Flexible Transparent Ultra-Barrier Films (on rolls) from Vitriflex • Low water vapor & oxygen transport rate (WVTR & OTR) • Low cost via roll-to-roll manufacturing • Direct lamination of electronic devices & flexible modules GLASS-BASED VITRIFLEX ELECTRONICS BARRIER FILM FLEXIBLE Glass OLED ELECTRONICS Substrate Device Roll to Roll Manufacturing RIGID FLEXIBLE 6
Vitriflex Barrier Technology Vitriflex has a novel, proprietary barrier film architecture • Proprietary mixed-oxide material set • Proprietary thin- film stack based on a “triad” structure – Diffusion barrier layer – Reactive layer – Diffusion barrier layer • Proprietary hybrid top seal Top Seal Polymer Substrate 7
Additional Benefit of Vitriflex Barrier Stack: Enhanced Optical Transmission Tuned at 600 nm Optical tuning enables improved light extraction 8
Going From Lab To Fab Proof of Feasibility Scaled Up Platform • • 10 -5 g/m 2 -day 10 -6 g/m 2 -day • • 125 mm web 1400 mm web • • R2R Prototype R2R Production 12 months PROTOTYPE PRODUCTION ROLL COATER ROLL COATER 9
Aegis: Internally-Designed Deposition System Key Features Modular Architecture 6 Deposition Zones Throughput ~1M m 2 /year Substrate Web Width up to 1.4 m Substrate Thicknesses 25-200 um Liner Removal & Replacement Particle Management 10
Production Ready AEGIS Deposition System 11
WVTR Uniformity Narrow Web (355 mm) Full range of all measured samples between 6.9 x 10 -6 and 9.7 x 10 -6 g/m 2 -day Outstanding uniformity and consistency at 355 mm width 12
Cross Web Uniformity: Wide Web 1200 mm ± 1.8% Superb results of scale-up to wide web in 2015 13
Cross Web Uniformity: Wide Web 1200 mm Outstanding uniformity and consistency at 1.2 m width 14
Down Web Uniformity: Wide Web 1200 mm At Production Speed, this is equivalent to a run of 1.7 Km!! 15
Vitriflex Wins Industry Award World’s Largest conference on the topic Award in front of Vitriflex’s internally David Parker, President & CEO designed “AEGIS Deposition System” Award Ceremony, Nov 18, 2015 Vitriflex received the “ Best Technical Development Manufacturing Award ” • Award recognizes the most significant development of a manufacturing device, process or production plant in the industry over the last 24 months. • Manufacturing developments optimize the process of lab-scale or mass-scale production by improving productivity, quality, reliability, uniformity, or scale. • Read more at: http://www.printedelectronicsworld.com/articles/8722/idtechex-printed-electronics-usa-2015-award-winners 16
Summary Significant Progress in Ultra-Barrier Film Manufacturing – AEGIS deposition system operational Innovation in materials, process and equipment design Proven excellent WVTR performance R2R capability 1400 mm web width – Strong IP portfolio Multiple patent applications in process – Production facility Located in Silicon Valley, CA – Positive customer feedback Customer sampling underway Applications in display, lighting and PV 17
Acknowledgements Vitriflex Investors – Mark George – Rex Chang – Jason Bloking – Martin Rosenblum – Olivier Postel – Teresa Ramos – Eric Ha – Rob Munns – David Parker 18
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