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Presentation to DuPont - Altium · PDF file Silvers •Silver/Silver Chloride –DuPont 5880, DuPont 5876, DuPont 5874 . Polyimide Ink -Printed heater on FR4 DuPont KA801 . Wearable

Oct 14, 2020

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  • Printed Electronics

    Overview of Inks, Substrates, Processes and Applications

    Insulectro

  • Two Broad Categories

    Fired On Polymer Thick Film

    • Very High Temperature Processing. – Ceramic substrates

    – Screening and “Tape” application of conductors and dielectrics.

    – Furnace sintering @ 850°C

    • Applications – RF circuits, O2 sensors,

    very high temp environments.

    • Polymer binder with conductive filler. – Wide range of substrates. – Flexible. – Operating temps from 50 to

    260°C depending on ink and substrate.

    – Very wide range of applications. • Wearables

    – Printable chemical sensors.

  • Polymer Thick Film (PTF) Circuitry

    Truly “additive” printed circuitry, where conductive material is printed onto various substrates, PET, polycarbonate, polyimide ,

    fluoropolymers, and paper.

    Exposed conductor Dielectric

  • Printed Electronics 1. Substrate acts a printing base

    2. Conductors are printed

    3. Dielectrics are overprinted twice

    4. Conductors may be applied again

    5. Dielectrics printed again as a

    coverlay

    • Through holes are drilled in the substrate and the right ink can make the connection.

    • Conductive adhesive is used for component assembly.

  • Materials of Printed Electronics

    Conductors & Dielectrics (Inks) Substrates

    • Polyimides

    • Epoxies

    • Acrylics

    • Thermoplastics

    • Kapton (Polyimide)

    • Paper

    • PEEK

    • PEN

    • Heat Stabilized PET

    • Polycarbonate

    • PVC

    O p

    e ra

    ti n

    g Te

    m p

    e ra

    tu re

  • Thermoplastic Acrylic

    • Fast drying

    • Flexible

    • High adhesion

    • Low Temp

    • Long shelf life

    • Can be soldered

    • Flexible

    • High adhesion

    • Medium Temp

    • Long shelf life

    Binder System Groups

    Epoxy Polyimide

    • High Strength

    • Can be plated

    • Can be soldered

    • Cold limited Storage

    • Flexible

    • Fast drying

    • Can be plated

    • Can be soldered

    • Long shelf life

  • Binder System Impacts

    • Thermal Performance – Operating Temperature • Adhesion • Flexibility • Drying/cure Time and Temperature • Storage Requirements – Shelf Life • Function

  • Overview of Ink Families • Standard inks

    • Low temperature dry/cure

    • Stretchable – Wearables

    – In-mold

    • High operating temperature

    • High conductivity

    • Sensors

    • Fired/sintered

  • Examples of DuPont Thermoplastic Inks

    • Carbons – DuPont 7102, DuPont 7105, DuPont 8144

    • Silvers – DuPont 5025, DuPont 5028, DuPont 5065

    Silvers

    • Silver/Silver Chloride – DuPont 5880, DuPont 5876, DuPont 5874

  • Polyimide Ink -Printed heater on FR4

    DuPont KA801

  • Wearable Printed Sensors & Interconnects

    • Fabric

    • Thermoplastic Polyurethane (INTEXAR™)

    • Stretchable Conductor (PE872, PE873)

    • Stretchable Sensor (PE971)

    • Encapsulant Overprint (PE773)

  • How do Conductive inks work?

    • For inks that are not sintered, (thermoplastic, thermoset, UV cured) – Close inter-particle contact is necessary – This is done as the binder (polymer) shrinks

    • Resistance can be increased by barrier coatings (oxides) on the particles of the conductive filler. – This is why silver is the most popular conductive particle, silver oxide is

    very conductive.

    As Applied Processed

  • SEM of Dried Ink

    Thermoplastic Screenprintable Ink (Ag loading 89%)

    Very dense packed Ag structure

  • SEM Highly Filled Silver Ink

    Super dense-packed Ag particle/network

  • Photonically Sintered Copper

    Printed Cu Antenna on FR-4 Effect of photonic sintering

    • Photonically heated copper ink overcomes the challenge of copper oxidation.

    • Ink is heated much faster than the substrate.

    • Ink is heated much faster than the substrate.

  • Ink Compatibility

    • Need to consider compatibility. Extremely Important, wrong product selection can lead to issues! – With Conductors, dielectrics, and substrates

    – With graphic inks, and conductive adhesives

    – The materials must work together.

    • No re-softening (dielectric over ink)

    • No change in resistance

    • No adhesion issues

    • No flexibility issues

  • Application of conductive inks

    • Screen printing (most common) • Flexographic printing • Rotogravure printing • Ink Jet (New)

    Rotary screen Flat-bed screen Flexography Rotogravure

    Printing speed and typical tooling cost

    High Speed Printing

  • Performance and Testing

    – Resistivity measurements – Flexibility/Creasibility – Environmental performance – Adhesion/Cohesion

  • Application of conductive inks

    • Screen printing • Flexographic printing • Rotogravure printing

    Rotary screen Flat-bed screen Flexography Rotogravure

    Printing speed

    High Speed Printing

  • Screenprinting

  • Example: Screen Recommendations

    • DuPont 5025, thermoplastic Silver, Thermally dried – 255/48 PE mesh, 5-7µm EOM, 25 Newtons, ~22° angle, use up to

    50% of frame ID for image area. This will provide a dry film thickness ~ 10 microns or 0.4 mils.

    • DuPont 5018, UV cured – 255/40 PE mesh, 5-7µm EOM, 25 Newtons, ~22° angle, use up to

    50% of frame ID for image area. This will provide a dry film thickness ~ 19 microns or 0.75 mils, per pass, two passes are recommended

    Mesh size controls print (wet) thickness

  • Screening is capable of fine lines

  • 38% Ag 80% Ag

    65% Ag

    10 mil Line/Space

    5 mil Line/Space

    5 and 5 with standard screening, below with special processing

    Silver content does not necessarily determine

    fine line capability.

  • Conveyor drier

    Static oven

    Processing: Drying and Curing

    UV-curing unit

    IR Dryer

    Many inks dry @ 300F

    Low temp inks dry @ 200F

  • Sensor Inks: Ag / AgCl • Inks based on silver/silver chloride can be used for onboard

    electrochemical sensors. • They can matched with chemistries to sense and measure many

    different ions/compounds.

  • Printed Electrodes for Solution Analysis

  • Markets for Printed Electronic Inks

    • Circuit Materials

    • Medical Applications/Sensors

    • High Speed Printed Electronics

    • RFID Applications

    • Automotive

    • Display, Lighting, Windows

  • Markets for Printed Electronic Inks

    • Printed Sensors – Homeland security applications – Blood glucose, urine, cumidin analysis

    • Printed heaters – Automotive seat heaters – Printed heaters for floors and ceilings – Printed heaters for modular or integrated systems

    • Solar Cell applications – Rigid – Flexible

  • • Many applications – Electronics everywhere (Internet of things)

    • New materials/processes are continually being developed

    • Many Inks that meet that meet the following needs • High conductivity

    • Flexible

    • High operating temperature

    • Low temp processing

    • Solderable

    Printed Electronics

  • Useful Links

    • Insulectro

    • DuPont Microcircuit Materials

    – Printed Electronics

    – Wearables

    – In-Mold

    – Fired On (Hybrid)

    – Biomedical

    http://www.insulectro.com/printed-electronics-materials.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics/products/stetchable-inks-for-wearable-electronics.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics/products/in-mold-electronic-technology.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics/products/in-mold-electronic-technology.html http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics/products/in-mold-electronic-technology.html http://www.dupont.com/products-and-services/electronic-electrical-materials/hybrid-circuit-materials.html http://www.dupont.com/products-and-services/electronic-electrical-materials/uses-and-applications/electronics-for-biomedical