Novel Polysulfide Substrates for Flexible Electronics. Tolis Voutsas, Ph.D. VP, Business Development Ares Materials, Inc.
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1 Novel Polysulfide Substrates for Flexible Electronics Tolis Voutsas, Ph.D. VP, Business Development Ares Materials, Inc.
2 Contents 6/21/2017 2
3 Company overview Founded 2014, spin-out of the University of Texas, Dallas Headquarters Dallas TX, USA Employees 7 FT & 4 PT Facilities 4000 sq. ft. lab, 600 sq. ft. cleanroom class Revenues projected by Q Capital raised $1.3 M seed round from VCs in Texas and California Key milestone Launch of flagship product, Pylux for customer validation 6/21/2017 3
4 Motivation: Plastic Display Technology Thinner, lighter, rugged and flexible Displays will become more ergonomic and seamlessly integrated with our ecosystem Plastic-based displays Thick glass modules will be replaced by plastic ones, cutting down weight and thickness by orders of magnitude and enabling new and versatile form factors Displays: USD $140B+ market IHS projected 600 million plastic-based displays will ship by 2023 LCD OLED Plastic Displays 0.5 lbs? 0.01 in? 20 lbs. & 0.1 in 32 lbs.& 1 depth Plasma 82 lbs. & 5 depth CRT 260 lbs. & 30 depth 6/21/2017 4
5 requires new materials The electronic display industry is mostly using materials technology originally developed 60 or 80 years ago Polyester films 1930 s Large industry players 1950 s Polyimide Their Question: What kind of incremental process improvements can be force-fit with the current materials? Our Question: What kind of completely new materials can we engineer to allow for product-level innovation? Incrementa l Innovation Disruptive Innovation 6/21/2017 5
6 Our technology: A electronic-grade polysulfide thermoset film designed for the next generation of thin, light, rugged, plastic based electronics. Dimensional stability Transparency Ease of processing Thermal durability Releasable Cost of ownership 6/21/2017 6
7 Pylux TECHNOLOGY 6/21/2017 7
8 Why is Pylux unique? Pylux Polymer 1 (e.g. PET) Polymer 2 (e.g. BO-PEN) Polymer 3 (e.g. PI) Pylux ease of processing is game changer On top of its unparalleled set of optical, thermal and mechanical properties, Pylux also reduces the complexity of processing on plastic. T g T m T d UV radiation Log Modulus Temperature 100% solids Easy mechanical de-bonding 0.3 nm R q From liquid to solid in just seconds Always a smooth surface Proprietary release layer, no LLO needed 6/21/2017 8
9 Why Pylux works (despite of higher CTE and lower T g )? Thermal stress in a film deposited on top of a flexible substrate: σσ ttt,ff = EE ss aa ff aa ss ΔTT Where: σ th,f thermal stress in film E s substrate modulus α f CTE of film α s CTE of substrate T change in temperature α s,pylux > α s,pi (e.g. α s,pylux ~ 150 ppm/ C, α s,pi ~15ppm/ C) But: Ε s,pylux << Ε s,pi Despite of its higher CTE, Pylux results in the development of much lower thermal stresses in the film stack formed on it. Lower built-in stress Improved accuracy of lithographic patterning 6/21/2017 9
10 Pylux exceptional optical performance Very high transmittance (T>90% in Visible) Low b* value (translates to low yellowing) Exceptional birefringence/optical retardation in addition Lower & tunable refractive index Low haze value 6/21/
11 Other Pylux characteristics Process Temperature Surface Roughness Ra~0.3nm Chemical Compatibility Current Pylux generation: Can be processed indefinitely at its isotherm max T (~275 C). Can be also processed for short periods of time at up to ~300 C. > 30 min stability against common photolithography solvents 6/21/
12 Polymer Film Thickness Range 100µm Pylux Have demonstrated a wide film-thickness range suitable for any of the targeted applications. Even at the thinnest end of the range, Pylux remains releasable from the rigid carrier with no observed issues. 55µm Pylux 30µm Pylux >2H Hardness 6/21/ µm Pylux (Spin-coated) 12
13 Manufacturing process benefits with Pylux ~1 hour process PI 6/21/
14 PRODUCT OPPORTUNITIES IN FLEXIBLE ELECTRONICS AND VALUE 6/21/
15 Pylux Display Applications A novel flexible material that can be used at or above the light emission layer LC display OLED display Light Cover lens Optically clear adhesive Touch sensor Polarizer Color filter glass Color Filter LC Material TFT Circuits TFT glass Polarizer Value proposition Dimensional stability Thermal budget Transparent Low haze and birefringence Chemical resilience Versatile surface chemistry Smooth surface Ease and speed of processing Releasable Cost of ownership Light Cover lens Optically clear adhesive Touch sensor Color filter glass Color Filter Encapsulation Cathode Organic light emitting diodes Anode TFT Circuits TFT glass Optional Back light unit 6/21/
16 Overall Business Development Strategy 6/21/
17 Mature: Flexible Color Filter Substrate Flex CF substrate represents a very robust product opportunity for Pylux due to: Pylux exceptional optical performance (optical clarity, yellow index, reliability, etc.) Pylux exceptional surface smoothness. Pylux high cost competitiveness against polyimides. Pylux ease of processing, including simple mechanical release from rigid carrier. Very limited competition in this space (Clear PI is the only alternative, BUT, expensive and difficult to process). $300-$500 million market by 2023 (only CF substrate). Evaluation Item Desired Target Current Result (with 100µm Pylux) Transmittance 550nm 550nm Optical Retardation nm 64.5 Solvent Resistance Heat Resistance Temp & Humidity E(a*,b*)<2 Light Resistance 1.7 UV Irradiation 2.8 CF Process Resistance No particles No distortions Release w/o LLO ok 3.4 (250 C, 1hr) 0.4 (ok) Ares has made significant strides in meeting most of the specifications for flex CF fabrication currently in the process of optimizing Pylux to address remaining issues 6/21/
18 Mature: Release Layer Technology Flexible display technology currently requires conventional (e.g. S2S) processing of plastic, supported by a rigid carrier. To that end, Ares Materials has also developed a temporary bonding & debonding solution for polysulfide films, initially developed to work with Pylux substrates. Key benefits: Simple mechanical debonding after process temperatures in excess of 300 C. Release stresses below 1 MPa. Volatile organic compounds (VOCs) free. No costly laser equipment is necessary (~ $100 MM), reducing the total cost of ownership. Our release layer and process works equally well with PI! 6/21/
19 19 Emerging: Photo-Patternable Polymer Ares started development of Pylux formulations that are optimized for photo-patterning. Preliminary results are very promising with almost no adjustments to our main formulation. UV-B exposure (~60sec) Developed with solvent rinse (~3 min) Photo mask pattern 6/21/2017 Patterned Pylux polymer film 19
20 Emerging: Stretchable electronics substrate Ares Materials has developed a monolithic material, capable of spatially-patterned areas of high and low modulus (ratios of stiff:soft upwards of 1000:1) via photolithographic patterning. Localizes global strain to soft regions proportional to the modulus ratio. Reduces complexity for stretchable electronics manufacturing. Prevents delamination related failures from adhesives currently used. Current state of the art Ares Proposition 6/21/
21 Ares Materials is rapidly developing a self-supporting, rollto-roll (R2R) alternative for Pylux for use in current R2R manufacturing lines where support webs are undesirable, or impossible, to use. High-Tg compositions (100 C to 150 C) for various ink applications. Enhanced mechanical properties (E, toughness, etc.) Maintains the desirable optical properties (high %T, low YI, etc.) Roll to Roll Developments 6/21/
22 Hybrid System Demo on Pylux Ares is actively pursuing the insertion of our polymer in the hybrid electronics space. Key advantages: Superior adhesion of different inks on the polysulfide polymer backbone. Good thermal characteristics Excellent optical performance Competitive pricing Pylux is targeting the gap that currently exists between PEN/PET and PI substrate materials in terms of performance and cost. Demonstration of a flex hybrid system on Pylux (system consisting of LEDs connected with Cu traces with a thin film battery) 6/21/
23 Summary Ares Materials has developed a novel polysulfide polymer that will enable the realization of next generation flex display and flex electronic products. Excellent optical characteristics Good thermal stability East of process Low manufacturing cost We have identified a number of product application areas for our main polymer material and we are working with partners towards commercialization on the mature side, as well as proof-of-concept and demonstrations on the emerging side. We plan to start Pylux resin manufacturing by Q We d love the opportunity to discuss how our material can help your application! Contact: tolis@aresmaterials.com 6/21/
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