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Printed electronics

Printed electronics is a set of printing methods used to create electrical devices on various substrates. Printing typically uses common printing equipment suitable for defining patterns on material, such as screen printing, flexography, gravure, offset lithography, and inkjet. By electronic-industry standards, these are low-cost processes. Electrically functional electronic or optical inks are deposited on the substrate, creating active or passive devices, such as thin film transistors; capacitors; coils; resistors. Some researchers expect printed electronics to facilitate widespread, very low-cost, low-performance electronics for applications such as flexible displays, smart labels, decorative and animated posters, and active clothing that do not require high performance.[1]

Gravure printing of electronic structures on paper

The term printed electronics is often related[by whom?] to organic electronics or plastic electronics, in which one or more inks are composed of carbon-based compounds.[2][need quotation to verify] These other terms refer to the ink material, which can be deposited by solution-based, vacuum-based, or other processes. Printed electronics, in contrast, specifies the process, and, subject to the specific requirements of the printing process selected, can utilize any solution-based material. This includes organic semiconductors, inorganic semiconductors, metallic conductors, nanoparticles, and nanotubes. The solution usually consist of filler materials dispersed in a suitable solvent. The most commonly used solvents include ethanol, xylene, Dimethylformamide (DMF),Dimethyl sulfoxide (DMSO), toluene and water, whereas, the most common conductive fillers include silver nanoparticles, silver flakes, carbon black, graphene, carbon nanotubes, conductive polymers (such as polyaniline and polypyrrole), and metal powders (such as copper or nickel). Considering the environmental impacts of the organic solvents, researchers are now focused on developing printable iks using water.[3][4][5]

For the preparation of printed electronics nearly all industrial printing methods are employed. Similar to conventional printing, printed electronics applies ink layers one atop another.[6] So the coherent development of printing methods and ink materials are the field's essential tasks.[7]

The most important benefit of printing is low-cost volume fabrication.[citation needed] The lower cost enables use in more applications.[8] An example is RFID-systems, which enable contactless identification in trade and transport. In some domains, such as light-emitting diodes printing does not impact performance.[6] Printing on flexible substrates allows electronics to be placed on curved surfaces, for example: printing solar cells on vehicle roofs. More typically, conventional semiconductors justify their much higher costs by providing much higher performance.

Printed and conventional electronics as complementary technologies.

Resolution, registration, thickness, holes, materials edit

The maximum required resolution of structures in conventional printing is determined by the human eye. Feature sizes smaller than approximately 20 µm cannot be distinguished by the human eye and consequently exceed the capabilities of conventional printing processes.[9] In contrast, higher resolution and smaller structures are necessary in most electronics printing, because they directly affect circuit density and functionality (especially transistors). A similar requirement holds for the precision with which layers are printed on top of each other (layer to layer registration).

Control of thickness, holes, and material compatibility (wetting, adhesion, solubility) are essential, but matter in conventional printing only if the eye can detect them. Conversely, the visual impression is irrelevant for printed electronics.[10]

Printing technologies edit

The attraction of printing technology for the fabrication of electronics mainly results from the possibility of preparing stacks of micro-structured layers (and thereby thin-film devices) in a much simpler and cost-effective way compared to conventional electronics.[11] Also, the ability to implement new or improved functionalities (e.g. mechanical flexibility) plays a role. The selection of the printing method used is determined by requirements concerning printed layers, by the properties of printed materials as well as economic and technical considerations of the final printed products.

Printing technologies divide between sheet-based and roll-to-roll-based approaches. Sheet-based inkjet and screen printing are best for low-volume, high-precision work. Gravure, offset and flexographic printing are more common for high-volume production, such as solar cells, reaching 10,000 square meters per hour (m2/h).[9][11] While offset and flexographic printing are mainly used for inorganic[12][13] and organic[14][15] conductors (the latter also for dielectrics),[16] gravure printing is especially suitable for quality-sensitive layers like organic semiconductors and semiconductor/dielectric-interfaces in transistors, due to high layer quality.[16] If high resolution is needed, gravure is also suitable for inorganic[17] and organic[18] conductors. Organic field-effect transistors and integrated circuits can be prepared completely by means of mass-printing methods.[16]

Inkjet printing edit

Inkjets are flexible and versatile, and can be set up with relatively low effort.[19] However, inkjets offer lower throughput of around 100 m2/h and lower resolution (ca. 50 µm).[9] It is well suited for low-viscosity, soluble materials like organic semiconductors. With high-viscosity materials, like organic dielectrics, and dispersed particles, like inorganic metal inks, difficulties due to nozzle clogging occur. Because ink is deposited via droplets, thickness and dispersion homogeneity is reduced. Using many nozzles simultaneously and pre-structuring the substrate allows improvements in productivity and resolution, respectively. However, in the latter case non-printing methods must be employed for the actual patterning step.[20] Inkjet printing is preferable for organic semiconductors in organic field-effect transistors (OFETs) and organic light-emitting diodes (OLEDs), but also OFETs completely prepared by this method have been demonstrated.[21] Frontplanes[22] and backplanes[23] of OLED-displays, integrated circuits,[24] organic photovoltaic cells (OPVCs)[25] and other devices can be prepared with inkjets.

Screen printing edit

Screen printing is appropriate for fabricating electrics and electronics due to its ability to produce patterned, thick layers from paste-like materials. This method can produce conducting lines from inorganic materials (e.g. for circuit boards and antennas), but also insulating and passivating layers, whereby layer thickness is more important than high resolution. Its 50 m2/h throughput and 100 µm resolution are similar to inkjets.[9] This versatile and comparatively simple method is used mainly for conductive and dielectric layers,[26][27] but also organic semiconductors, e.g. for OPVCs,[28] and even complete OFETs[22] can be printed.

Aerosol jet printing edit

Aerosol Jet Printing (also known as Maskless Mesoscale Materials Deposition or M3D)[29] is another material deposition technology for printed electronics. The Aerosol Jet process begins with atomization of an ink, via ultrasonic or pneumatic means, producing droplets on the order of one to two micrometers in diameter. The droplets then flow through a virtual impactor which deflects the droplets having lower momentum away from the stream. This step helps maintaining a tight droplet size distribution. The droplets are entrained in a gas stream and delivered to the print head. Here, an annular flow of clean gas is introduced around the aerosol stream to focus the droplets into a tightly collimated beam of material. The combined gas streams exit the print head through a converging nozzle that compresses the aerosol stream to a diameter as small as 10 µm. The jet of droplets exits the print head at high velocity (~50 meters/second) and impinges upon the substrate.

Electrical interconnects, passive and active components[30] are formed by moving the print head, equipped with a mechanical stop/start shutter, relative to the substrate. The resulting patterns can have features ranging from 10 µm wide, with layer thicknesses from tens of nanometers to >10 µm.[31] A wide nozzle print head enables efficient patterning of millimeter size electronic features and surface coating applications. All printing occurs without the use of vacuum or pressure chambers. The high exit velocity of the jet enables a relatively large separation between the print head and the substrate, typically 2–5 mm. The droplets remain tightly focused over this distance, resulting in the ability to print conformal patterns over three dimensional substrates.

Despite the high velocity, the printing process is gentle; substrate damage does not occur and there is generally minimal splatter or overspray from the droplets.[32] Once patterning is complete, the printed ink typically requires post treatment to attain final electrical and mechanical properties. Post-treatment is driven more by the specific ink and substrate combination than by the printing process. A wide range of materials has been successfully deposited with the Aerosol Jet process, including diluted thick film pastes, conducting polymer inks,[33] thermosetting polymers such as UV-curable epoxies, and solvent-based polymers like polyurethane and polyimide, and biologic materials.[34]

Recently, printing paper was proposed to be used as the substrate of the printing. Highly conductive (close to bulk copper) and high-resolution traces can be printed on foldable and available office printing papers, with 80°Celsius curing temperature and 40 minutes of curing time.[35]

Evaporation printing edit

Evaporation printing uses a combination of high precision screen printing with material vaporization to print features to 5 µm. This method uses techniques such as thermal, e-beam, sputter and other traditional production technologies to deposit materials through a high precision shadow mask (or stencil) that is registered to the substrate to better than 1 µm. By layering different mask designs and/or adjusting materials, reliable, cost-effective circuits can be built additively, without the use of photo-lithography.

Other methods edit

Other methods with similarities to printing, among them microcontact printing and nano-imprint lithography are of interest.[36] Here, µm- and nm-sized layers, respectively, are prepared by methods similar to stamping with soft and hard forms, respectively. Often the actual structures are prepared subtractively, e.g. by deposition of etch masks or by lift-off processes. For example, electrodes for OFETs can be prepared.[37][38] Sporadically pad printing is used in a similar manner.[39] Occasionally so-called transfer methods, where solid layers are transferred from a carrier to the substrate, are considered printed electronics.[40] Electrophotography is currently not used in printed electronics.

Materials edit

Both organic and inorganic materials are used for printed electronics. Ink materials must be available in liquid form, for solution, dispersion or suspension.[41] They must function as conductors, semiconductors, dielectrics, or insulators. Material costs must be fit for the application.

Electronic functionality and printability can interfere with each other, mandating careful optimization.[10] For example, a higher molecular weight in polymers enhances conductivity, but diminishes solubility. For printing, viscosity, surface tension and solid content must be tightly controlled. Cross-layer interactions such as wetting, adhesion, and solubility as well as post-deposition drying procedures affect the outcome. Additives often used in conventional printing inks are unavailable, because they often defeat electronic functionality.

Material properties largely determine the differences between printed and conventional electronics. Printable materials provide decisive advantages beside printability, such as mechanical flexibility and functional adjustment by chemical modification (e.g. light color in OLEDs).[42]

Printed conductors offer lower conductivity and charge carrier mobility.[43]

With a few exceptions, inorganic ink materials are dispersions of metallic or semiconducting micro- and nano-particles. Semiconducting nanoparticles used include silicon[44] and oxide semiconductors.[45] Silicon is also printed as an organic precursor[46] which is then converted by pyrolisis and annealing into crystalline silicon.

PMOS but not CMOS is possible in printed electronics.[47]

Organic materials edit

Organic printed electronics integrates knowledge and developments from printing, electronics, chemistry, and materials science, especially from organic and polymer chemistry. Organic materials in part differ from conventional electronics in terms of structure, operation and functionality,[48] which influences device and circuit design and optimization as well as fabrication method.[49]

The discovery of conjugated polymers[43] and their development into soluble materials provided the first organic ink materials. Materials from this class of polymers variously possess conducting, semiconducting, electroluminescent, photovoltaic and other properties. Other polymers are used mostly as insulators and dielectrics.

In most organic materials, hole transport is favored over electron transport.[50] Recent studies indicate that this is a specific feature of organic semiconductor/dielectric-interfaces, which play a major role in OFETs.[51] Therefore, p-type devices should dominate over n-type devices. Durability (resistance to dispersion) and lifetime is less than conventional materials.[47]

Organic semiconductors include the conductive polymers poly(3,4-ethylene dioxitiophene), doped with poly(styrene sulfonate), (PEDOT:PSS) and poly(aniline) (PANI). Both polymers are commercially available in different formulations and have been printed using inkjet,[52] screen[26] and offset printing[14] or screen,[26] flexo[15] and gravure[18] printing, respectively.

Polymer semiconductors are processed using inkjet printing, such as poly(thiopene)s like poly(3-hexylthiophene) (P3HT)[53] and poly(9,9-dioctylfluorene co-bithiophen) (F8T2).[54] The latter material has also been gravure printed.[16] Different electroluminescent polymers are used with inkjet printing,[20] as well as active materials for photovoltaics (e.g. blends of P3HT with fullerene derivatives),[55] which in part also can be deposited using screen printing (e.g. blends of poly(phenylene vinylene) with fullerene derivatives).[28]

Printable organic and inorganic insulators and dielectrics exist, which can be processed with different printing methods.[56]

Inorganic materials edit

Inorganic electronics provides highly ordered layers and interfaces that organic and polymer materials cannot provide.

Silver nanoparticles are used with flexo,[13] offset[57] and inkjet.[58] Gold particles are used with inkjet.[59]

A.C. electroluminescent (EL) multi-color displays can cover many tens of square meters, or be incorporated in watch faces and instrument displays. They involve six to eight printed inorganic layers, including a copper doped phosphor, on a plastic film substrate.[60]

CIGS cells can be printed directly onto molybdenum coated glass sheets.

A printed gallium arsenide germanium solar cell demonstrated 40.7% conversion efficiency, eight times that of the best organic cells, approaching the best performance of crystalline silicon.[60]

Substrates edit

Printed electronics allows the use of flexible substrates, which lowers production costs and allows fabrication of mechanically flexible circuits. While inkjet and screen printing typically imprint rigid substrates like glass and silicon, mass-printing methods nearly exclusively use flexible foil and paper. Poly(ethylene terephthalate)-foil (PET) is a common choice, due to its low cost and moderately high temperature stability.[61] Poly(ethylene naphthalate)- (PEN) and poly(imide)-foil (PI) are higher performance, higher cost alternatives. Paper's low costs and manifold applications make it an attractive substrate, however, its high roughness and high wettability have traditionally made it problematic for electronics. This is an active research area,[62] however, and print-compatible metal deposition techniques have been demonstrated that adapt to the rough 3D surface geometry of paper.[63][64]

Other important substrate criteria are low roughness and suitable wet-ability, which can be tuned pre-treatment by use of coating or Corona discharge. In contrast to conventional printing, high absorbency is usually disadvantageous.

History edit

Albert Hanson, a German by birth, is credited to have introduced the concept of printed electronics. in 1903 he filled a patent for “Printed Wires,” and thus printed electronics were born.[65] Hanson proposed forming a Printed Circuit Board pattern on copper foil through cutting or stamping. The drawn elements were glued to the dielectric, in this case, paraffined paper.[66] The first printed circuit was produced in 1936 by Paul Eisler, and that process was used for large-scale production of radios by the USA during World War II. Printed circuit technology was released for commercial use in the US in 1948 (Printed Circuits Handbook, 1995). In the over a half-century since its inception, printed electronics has evolved from the production of printed circuit boards (PCBs), through the everyday use of membrane switches, to today's RFID, photovoltaic and electroluminescent technologies.[67] Today it is nearly impossible to look around a modern American household and not see devices that either uses printed electronic components or that are the direct result of printed electronic technologies. Widespread production of printed electronics for household use began in the 1960s when the Printed Circuit Board became the foundation for all consumer electronics. Since then printed electronics have become a cornerstone in many new commercial products.[68]

The biggest trend in recent history when it comes to printed electronics is the widespread use of them in solar cells. In 2011, researchers from MIT created a flexible solar cell by inkjet printing on normal paper.[69] In 2018, researchers at Rice University have developed organic solar cells which can be painted or printed onto surfaces. These solar cells have been shown to max out at fifteen percent efficiency.[70] Konarka Technologies, now a defunct company in the US, was the pioneering company in producing inkjet solar cells. Today there are more than fifty companies across a diverse number of countries that are producing printed solar cells.

While printed electronics have been around since the 1960s, they are predicted[when?] to have a major boom in total revenue. As of 2011, the total printed electronic revenue was reported to be at $12.385 (billion).[71] A report by IDTechEx predicts the PE market will reach $330 (billion) in 2027.[72] A big reason for this increase in revenue is because of the incorporation of printed electronic into cellphones. Nokia was one of the companies that pioneered the idea of creating a “Morph” phone using printed electronics. Since then, Apple has implemented this technology into their iPhone XS, XS Max, and XR devices.[73] Printed electronics can be used to make all of the following components of a cellphone: 3D main antenna, GPS antenna, energy storage, 3D interconnections, multi-layer PCB, edge circuits, ITO jumpers, hermetic seals, LED packaging, and tactile feedback.

With the revolutionary discoveries and advantages that printed electronic gives to companies many large companies have made recent investments into this technology. In 2007, Soligie Inc. and Thinfilm Electronics entered into an agreement to combine IPs for soluble memory materials and functional materials printing to develop printed memory in commercial volumes.[67] LG announce significant investment, potentially $8.71 billion in OLEDs on Plastic. Sharp (Foxconn) will invest $570m in pilot line for OLED displays. BOE announce potential $6.8 billion in flexible AMOLED fab. Heliatek has secured €80m in additional funding for OPV manufacturing in Dresden. PragmatIC has raised ~ €20m from investors including Avery Dennison. Thinfilm invests in new production site in Silicon Valley (formerly owned by Qualcomm). Cambrios back in business after acquisition by TPK.[72]

Applications edit

Printed electronics are in use or under consideration include wireless sensors in packaging, skin patches that communicate with the internet, and buildings that detect leaks to enable preventative maintenance. Most of these applications are still in the prototyping and development stages.[74] There is a particularly growing interest for flexible smart electronic systems, including photovoltaic, sensing and processing devices, driven by the desire to extend and integrate the latest advances in (opto-)electronic technologies into a broad range of low-cost (even disposable) consumer products of our everyday life, and as tools to bring together the digital and physical worlds.[75]

Norwegian company ThinFilm demonstrated roll-to-roll printed organic memory in 2009.[76][77][78][79]

Standards development and activities edit

Technical standards and road-mapping initiatives are intended to facilitate value chain development (for sharing of product specifications, characterization standards, etc.) This strategy of standards development mirrors the approach used by silicon-based electronics over the past 50 years. Initiatives include:

IPC—Association Connecting Electronics Industries has published three standards for printed electronics. All three have been published in cooperation with the Japan Electronic Packaging and Circuits Association (JPCA):

  • IPC/JPCA-4921, Requirements for Printed Electronics Base Materials
  • IPC/JPCA-4591, Requirements for Printed Electronics Functional Conductive Materials
  • IPC/JPCA-2291, Design Guideline for Printed Electronics

These standards, and others in development, are part of IPC's Printed Electronics Initiative.

See also edit

References edit

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Further reading edit

  • Printed Organic and Molecular Electronics, edited by D. Gamota, P. Brazis, K. Kalyanasundaram, and J. Zhang (Kluwer Academic Publishers: New York, 2004). ISBN 1-4020-7707-6

External links edit

  • Cleaner Electronics Research Group - Brunel University
  • Printed Electronics conference/exhibition
  • (Ferro Corporation)
  • Western Michigan University's includes AccuPress gravure printer
  • Major Trends in Gravure Printed Electronics June 2010
  • Printed Electronics – avistando el futuro. Printed Electronics en Español
  • Organic Solar Cells - Theory and Practice (Coursera)

printed, electronics, confused, with, printed, circuit, board, printing, methods, used, create, electrical, devices, various, substrates, printing, typically, uses, common, printing, equipment, suitable, defining, patterns, material, such, screen, printing, fl. Not to be confused with Printed circuit board Printed electronics is a set of printing methods used to create electrical devices on various substrates Printing typically uses common printing equipment suitable for defining patterns on material such as screen printing flexography gravure offset lithography and inkjet By electronic industry standards these are low cost processes Electrically functional electronic or optical inks are deposited on the substrate creating active or passive devices such as thin film transistors capacitors coils resistors Some researchers expect printed electronics to facilitate widespread very low cost low performance electronics for applications such as flexible displays smart labels decorative and animated posters and active clothing that do not require high performance 1 Gravure printing of electronic structures on paperThe term printed electronics is often related by whom to organic electronics or plastic electronics in which one or more inks are composed of carbon based compounds 2 need quotation to verify These other terms refer to the ink material which can be deposited by solution based vacuum based or other processes Printed electronics in contrast specifies the process and subject to the specific requirements of the printing process selected can utilize any solution based material This includes organic semiconductors inorganic semiconductors metallic conductors nanoparticles and nanotubes The solution usually consist of filler materials dispersed in a suitable solvent The most commonly used solvents include ethanol xylene Dimethylformamide DMF Dimethyl sulfoxide DMSO toluene and water whereas the most common conductive fillers include silver nanoparticles silver flakes carbon black graphene carbon nanotubes conductive polymers such as polyaniline and polypyrrole and metal powders such as copper or nickel Considering the environmental impacts of the organic solvents researchers are now focused on developing printable iks using water 3 4 5 For the preparation of printed electronics nearly all industrial printing methods are employed Similar to conventional printing printed electronics applies ink layers one atop another 6 So the coherent development of printing methods and ink materials are the field s essential tasks 7 The most important benefit of printing is low cost volume fabrication citation needed The lower cost enables use in more applications 8 An example is RFID systems which enable contactless identification in trade and transport In some domains such as light emitting diodes printing does not impact performance 6 Printing on flexible substrates allows electronics to be placed on curved surfaces for example printing solar cells on vehicle roofs More typically conventional semiconductors justify their much higher costs by providing much higher performance Printed and conventional electronics as complementary technologies Contents 1 Resolution registration thickness holes materials 2 Printing technologies 2 1 Inkjet printing 2 2 Screen printing 2 3 Aerosol jet printing 2 4 Evaporation printing 2 5 Other methods 3 Materials 3 1 Organic materials 3 2 Inorganic materials 3 3 Substrates 4 History 5 Applications 6 Standards development and activities 7 See also 8 References 9 Further reading 10 External linksResolution registration thickness holes materials editThe maximum required resolution of structures in conventional printing is determined by the human eye Feature sizes smaller than approximately 20 µm cannot be distinguished by the human eye and consequently exceed the capabilities of conventional printing processes 9 In contrast higher resolution and smaller structures are necessary in most electronics printing because they directly affect circuit density and functionality especially transistors A similar requirement holds for the precision with which layers are printed on top of each other layer to layer registration Control of thickness holes and material compatibility wetting adhesion solubility are essential but matter in conventional printing only if the eye can detect them Conversely the visual impression is irrelevant for printed electronics 10 Printing technologies editThe attraction of printing technology for the fabrication of electronics mainly results from the possibility of preparing stacks of micro structured layers and thereby thin film devices in a much simpler and cost effective way compared to conventional electronics 11 Also the ability to implement new or improved functionalities e g mechanical flexibility plays a role The selection of the printing method used is determined by requirements concerning printed layers by the properties of printed materials as well as economic and technical considerations of the final printed products Printing technologies divide between sheet based and roll to roll based approaches Sheet based inkjet and screen printing are best for low volume high precision work Gravure offset and flexographic printing are more common for high volume production such as solar cells reaching 10 000 square meters per hour m2 h 9 11 While offset and flexographic printing are mainly used for inorganic 12 13 and organic 14 15 conductors the latter also for dielectrics 16 gravure printing is especially suitable for quality sensitive layers like organic semiconductors and semiconductor dielectric interfaces in transistors due to high layer quality 16 If high resolution is needed gravure is also suitable for inorganic 17 and organic 18 conductors Organic field effect transistors and integrated circuits can be prepared completely by means of mass printing methods 16 Inkjet printing edit Inkjets are flexible and versatile and can be set up with relatively low effort 19 However inkjets offer lower throughput of around 100 m2 h and lower resolution ca 50 µm 9 It is well suited for low viscosity soluble materials like organic semiconductors With high viscosity materials like organic dielectrics and dispersed particles like inorganic metal inks difficulties due to nozzle clogging occur Because ink is deposited via droplets thickness and dispersion homogeneity is reduced Using many nozzles simultaneously and pre structuring the substrate allows improvements in productivity and resolution respectively However in the latter case non printing methods must be employed for the actual patterning step 20 Inkjet printing is preferable for organic semiconductors in organic field effect transistors OFETs and organic light emitting diodes OLEDs but also OFETs completely prepared by this method have been demonstrated 21 Frontplanes 22 and backplanes 23 of OLED displays integrated circuits 24 organic photovoltaic cells OPVCs 25 and other devices can be prepared with inkjets Screen printing edit Screen printing is appropriate for fabricating electrics and electronics due to its ability to produce patterned thick layers from paste like materials This method can produce conducting lines from inorganic materials e g for circuit boards and antennas but also insulating and passivating layers whereby layer thickness is more important than high resolution Its 50 m2 h throughput and 100 µm resolution are similar to inkjets 9 This versatile and comparatively simple method is used mainly for conductive and dielectric layers 26 27 but also organic semiconductors e g for OPVCs 28 and even complete OFETs 22 can be printed Aerosol jet printing edit Aerosol Jet Printing also known as Maskless Mesoscale Materials Deposition or M3D 29 is another material deposition technology for printed electronics The Aerosol Jet process begins with atomization of an ink via ultrasonic or pneumatic means producing droplets on the order of one to two micrometers in diameter The droplets then flow through a virtual impactor which deflects the droplets having lower momentum away from the stream This step helps maintaining a tight droplet size distribution The droplets are entrained in a gas stream and delivered to the print head Here an annular flow of clean gas is introduced around the aerosol stream to focus the droplets into a tightly collimated beam of material The combined gas streams exit the print head through a converging nozzle that compresses the aerosol stream to a diameter as small as 10 µm The jet of droplets exits the print head at high velocity 50 meters second and impinges upon the substrate Electrical interconnects passive and active components 30 are formed by moving the print head equipped with a mechanical stop start shutter relative to the substrate The resulting patterns can have features ranging from 10 µm wide with layer thicknesses from tens of nanometers to gt 10 µm 31 A wide nozzle print head enables efficient patterning of millimeter size electronic features and surface coating applications All printing occurs without the use of vacuum or pressure chambers The high exit velocity of the jet enables a relatively large separation between the print head and the substrate typically 2 5 mm The droplets remain tightly focused over this distance resulting in the ability to print conformal patterns over three dimensional substrates Despite the high velocity the printing process is gentle substrate damage does not occur and there is generally minimal splatter or overspray from the droplets 32 Once patterning is complete the printed ink typically requires post treatment to attain final electrical and mechanical properties Post treatment is driven more by the specific ink and substrate combination than by the printing process A wide range of materials has been successfully deposited with the Aerosol Jet process including diluted thick film pastes conducting polymer inks 33 thermosetting polymers such as UV curable epoxies and solvent based polymers like polyurethane and polyimide and biologic materials 34 Recently printing paper was proposed to be used as the substrate of the printing Highly conductive close to bulk copper and high resolution traces can be printed on foldable and available office printing papers with 80 Celsius curing temperature and 40 minutes of curing time 35 Evaporation printing edit Evaporation printing uses a combination of high precision screen printing with material vaporization to print features to 5 µm This method uses techniques such as thermal e beam sputter and other traditional production technologies to deposit materials through a high precision shadow mask or stencil that is registered to the substrate to better than 1 µm By layering different mask designs and or adjusting materials reliable cost effective circuits can be built additively without the use of photo lithography Other methods edit Other methods with similarities to printing among them microcontact printing and nano imprint lithography are of interest 36 Here µm and nm sized layers respectively are prepared by methods similar to stamping with soft and hard forms respectively Often the actual structures are prepared subtractively e g by deposition of etch masks or by lift off processes For example electrodes for OFETs can be prepared 37 38 Sporadically pad printing is used in a similar manner 39 Occasionally so called transfer methods where solid layers are transferred from a carrier to the substrate are considered printed electronics 40 Electrophotography is currently not used in printed electronics Materials editBoth organic and inorganic materials are used for printed electronics Ink materials must be available in liquid form for solution dispersion or suspension 41 They must function as conductors semiconductors dielectrics or insulators Material costs must be fit for the application Electronic functionality and printability can interfere with each other mandating careful optimization 10 For example a higher molecular weight in polymers enhances conductivity but diminishes solubility For printing viscosity surface tension and solid content must be tightly controlled Cross layer interactions such as wetting adhesion and solubility as well as post deposition drying procedures affect the outcome Additives often used in conventional printing inks are unavailable because they often defeat electronic functionality Material properties largely determine the differences between printed and conventional electronics Printable materials provide decisive advantages beside printability such as mechanical flexibility and functional adjustment by chemical modification e g light color in OLEDs 42 Printed conductors offer lower conductivity and charge carrier mobility 43 With a few exceptions inorganic ink materials are dispersions of metallic or semiconducting micro and nano particles Semiconducting nanoparticles used include silicon 44 and oxide semiconductors 45 Silicon is also printed as an organic precursor 46 which is then converted by pyrolisis and annealing into crystalline silicon PMOS but not CMOS is possible in printed electronics 47 Organic materials edit Organic printed electronics integrates knowledge and developments from printing electronics chemistry and materials science especially from organic and polymer chemistry Organic materials in part differ from conventional electronics in terms of structure operation and functionality 48 which influences device and circuit design and optimization as well as fabrication method 49 The discovery of conjugated polymers 43 and their development into soluble materials provided the first organic ink materials Materials from this class of polymers variously possess conducting semiconducting electroluminescent photovoltaic and other properties Other polymers are used mostly as insulators and dielectrics In most organic materials hole transport is favored over electron transport 50 Recent studies indicate that this is a specific feature of organic semiconductor dielectric interfaces which play a major role in OFETs 51 Therefore p type devices should dominate over n type devices Durability resistance to dispersion and lifetime is less than conventional materials 47 Organic semiconductors include the conductive polymers poly 3 4 ethylene dioxitiophene doped with poly styrene sulfonate PEDOT PSS and poly aniline PANI Both polymers are commercially available in different formulations and have been printed using inkjet 52 screen 26 and offset printing 14 or screen 26 flexo 15 and gravure 18 printing respectively Polymer semiconductors are processed using inkjet printing such as poly thiopene s like poly 3 hexylthiophene P3HT 53 and poly 9 9 dioctylfluorene co bithiophen F8T2 54 The latter material has also been gravure printed 16 Different electroluminescent polymers are used with inkjet printing 20 as well as active materials for photovoltaics e g blends of P3HT with fullerene derivatives 55 which in part also can be deposited using screen printing e g blends of poly phenylene vinylene with fullerene derivatives 28 Printable organic and inorganic insulators and dielectrics exist which can be processed with different printing methods 56 Inorganic materials edit Inorganic electronics provides highly ordered layers and interfaces that organic and polymer materials cannot provide Silver nanoparticles are used with flexo 13 offset 57 and inkjet 58 Gold particles are used with inkjet 59 A C electroluminescent EL multi color displays can cover many tens of square meters or be incorporated in watch faces and instrument displays They involve six to eight printed inorganic layers including a copper doped phosphor on a plastic film substrate 60 CIGS cells can be printed directly onto molybdenum coated glass sheets A printed gallium arsenide germanium solar cell demonstrated 40 7 conversion efficiency eight times that of the best organic cells approaching the best performance of crystalline silicon 60 Substrates edit Printed electronics allows the use of flexible substrates which lowers production costs and allows fabrication of mechanically flexible circuits While inkjet and screen printing typically imprint rigid substrates like glass and silicon mass printing methods nearly exclusively use flexible foil and paper Poly ethylene terephthalate foil PET is a common choice due to its low cost and moderately high temperature stability 61 Poly ethylene naphthalate PEN and poly imide foil PI are higher performance higher cost alternatives Paper s low costs and manifold applications make it an attractive substrate however its high roughness and high wettability have traditionally made it problematic for electronics This is an active research area 62 however and print compatible metal deposition techniques have been demonstrated that adapt to the rough 3D surface geometry of paper 63 64 Other important substrate criteria are low roughness and suitable wet ability which can be tuned pre treatment by use of coating or Corona discharge In contrast to conventional printing high absorbency is usually disadvantageous History editAlbert Hanson a German by birth is credited to have introduced the concept of printed electronics in 1903 he filled a patent for Printed Wires and thus printed electronics were born 65 Hanson proposed forming a Printed Circuit Board pattern on copper foil through cutting or stamping The drawn elements were glued to the dielectric in this case paraffined paper 66 The first printed circuit was produced in 1936 by Paul Eisler and that process was used for large scale production of radios by the USA during World War II Printed circuit technology was released for commercial use in the US in 1948 Printed Circuits Handbook 1995 In the over a half century since its inception printed electronics has evolved from the production of printed circuit boards PCBs through the everyday use of membrane switches to today s RFID photovoltaic and electroluminescent technologies 67 Today it is nearly impossible to look around a modern American household and not see devices that either uses printed electronic components or that are the direct result of printed electronic technologies Widespread production of printed electronics for household use began in the 1960s when the Printed Circuit Board became the foundation for all consumer electronics Since then printed electronics have become a cornerstone in many new commercial products 68 The biggest trend in recent history when it comes to printed electronics is the widespread use of them in solar cells In 2011 researchers from MIT created a flexible solar cell by inkjet printing on normal paper 69 In 2018 researchers at Rice University have developed organic solar cells which can be painted or printed onto surfaces These solar cells have been shown to max out at fifteen percent efficiency 70 Konarka Technologies now a defunct company in the US was the pioneering company in producing inkjet solar cells Today there are more than fifty companies across a diverse number of countries that are producing printed solar cells While printed electronics have been around since the 1960s they are predicted when to have a major boom in total revenue As of 2011 the total printed electronic revenue was reported to be at 12 385 billion 71 A report by IDTechEx predicts the PE market will reach 330 billion in 2027 72 A big reason for this increase in revenue is because of the incorporation of printed electronic into cellphones Nokia was one of the companies that pioneered the idea of creating a Morph phone using printed electronics Since then Apple has implemented this technology into their iPhone XS XS Max and XR devices 73 Printed electronics can be used to make all of the following components of a cellphone 3D main antenna GPS antenna energy storage 3D interconnections multi layer PCB edge circuits ITO jumpers hermetic seals LED packaging and tactile feedback With the revolutionary discoveries and advantages that printed electronic gives to companies many large companies have made recent investments into this technology In 2007 Soligie Inc and Thinfilm Electronics entered into an agreement to combine IPs for soluble memory materials and functional materials printing to develop printed memory in commercial volumes 67 LG announce significant investment potentially 8 71 billion in OLEDs on Plastic Sharp Foxconn will invest 570m in pilot line for OLED displays BOE announce potential 6 8 billion in flexible AMOLED fab Heliatek has secured 80m in additional funding for OPV manufacturing in Dresden PragmatIC has raised 20m from investors including Avery Dennison Thinfilm invests in new production site in Silicon Valley formerly owned by Qualcomm Cambrios back in business after acquisition by TPK 72 Applications editPrinted electronics are in use or under consideration include wireless sensors in packaging skin patches that communicate with the internet and buildings that detect leaks to enable preventative maintenance Most of these applications are still in the prototyping and development stages 74 There is a particularly growing interest for flexible smart electronic systems including photovoltaic sensing and processing devices driven by the desire to extend and integrate the latest advances in opto electronic technologies into a broad range of low cost even disposable consumer products of our everyday life and as tools to bring together the digital and physical worlds 75 Norwegian company ThinFilm demonstrated roll to roll printed organic memory in 2009 76 77 78 79 Standards development and activities editTechnical standards and road mapping initiatives are intended to facilitate value chain development for sharing of product specifications characterization standards etc This strategy of standards development mirrors the approach used by silicon based electronics over the past 50 years Initiatives include The IEEE Standards Association has published IEEE 1620 2004 80 and IEEE 1620 1 2006 81 Similar to the well established International Technology Roadmap for Semiconductors ITRS the International Electronics Manufacturing Initiative iNEMI 82 has published a roadmap for printed and other organic electronics IPC Association Connecting Electronics Industries has published three standards for printed electronics All three have been published in cooperation with the Japan Electronic Packaging and Circuits Association JPCA IPC JPCA 4921 Requirements for Printed Electronics Base Materials IPC JPCA 4591 Requirements for Printed Electronics Functional Conductive Materials IPC JPCA 2291 Design Guideline for Printed ElectronicsThese standards and others in development are part of IPC s Printed Electronics Initiative See also edit nbsp Electronics portalAmorphous silicon Anilox rolls Chip tag Circuit deposition Coating and printing processes Conductive ink Electronic paper Flexible battery Flexible electronics Laminar electronics Microcontact Nanoparticle silicon OligomerReferences edit Coatanea E Kantola V Kulovesi J Lahti L Lin R amp Zavodchikova M 2009 Printed Electronics Now and Future In Neuvo Y amp Ylonen S eds Bit Bang Rays to the Future Helsinki University of Technology TKK MIDE Helsinki University Print Helsinki Finland 63 102 ISBN 978 952 248 078 1 http lib tkk fi Reports 2009 isbn9789522480781 pdf Moreover PE technology could provide a number of enabling factors like flexibility and robustness allowing incorporation of electronics functions into objects that do not yet contain any active electronic components e g toy applications printed advertising material or electronic labels Printed amp Flexible Electronics IDTechEx Research Reports and Subscriptions www idtechex com Retrieved 2020 09 21 Khan Junaid Mariatti M Zubir Syazana A Rusli Arjulizan Manaf Asrulnizam Abd Khirotdin Rd Khairilhijra 29 January 2024 Eco friendly alkali lignin assisted water based graphene oxide ink and its application as a resistive temperature sensor Nanotechnology 35 5 055301 doi 10 1088 1361 6528 ad06d4 Khan Junaid Mariatti M 1 September 2023 In situ graphene oxide reduction via inkjet printing using natural reducing inks Flexible and Printed Electronics 8 3 035009 doi 10 1088 2058 8585 acf143 Khan Junaid Mariatti M November 2022 Effect of natural surfactant on the performance of reduced graphene oxide conductive ink Journal of Cleaner Production 376 134254 doi 10 1016 j jclepro 2022 134254 a b Roth H K et al 2001 Organische Funktionsschichten in Polymerelektronik und Polymersolarzellen Materialwissenschaft und Werkstofftechnik 32 10 789 doi 10 1002 1521 4052 200110 32 10 lt 789 AID MAWE789 gt 3 0 CO 2 E Thomas D J 2016 Integration of Silicon and Printed Electronics for Rapid Diagnostic Disease Biosensing Point of Care The Journal of Near Patient Testing amp Technology 15 2 61 71 doi 10 1097 POC 0000000000000091 S2CID 77379659 Xu J M Jimmy 2000 Plastic electronics and future trends in microelectronics Synthetic Metals 115 1 3 1 3 doi 10 1016 s0379 6779 00 00291 5 a b c d A Blayo and B Pineaux Joint sOC EUSAI Conference Grenoble 2005 a b U Fugmann et al mstNews 2 2006 13 a b J R Sheats Journal of Materials Research 2004 19 1974 Harrey P M et al 2002 Capacitive type humidity sensors fabricated using the offset lithographic printing process Sensors and Actuators B 87 2 226 232 doi 10 1016 s0925 4005 02 00240 x a b J Siden et al Polytronic Conference Wroclaw 2005 a b Zielke D et al 2005 Polymer based organic field effect transistor using offset printed source drain structures Applied Physics Letters 87 12 123508 doi 10 1063 1 2056579 a b Makela T et al 2005 Utilizing roll to roll techniques for manufacturing source drain electrodes for all polymer transistors Synthetic Metals 153 1 3 285 288 doi 10 1016 j synthmet 2005 07 140 a b c d Hubler A et al 2007 Ring oscillator fabricated completely by means of mass printing technologies Organic Electronics 8 5 480 doi 10 1016 j orgel 2007 02 009 S Leppavuori et al Sensors and Actuators 41 42 1994 593 a b Makela T et al 2003 Roll to roll method for producing polyaniline patterns on paper Synthetic Metals 135 41 doi 10 1016 s0379 6779 02 00753 1 Parashkov R et al 2005 Large Area Electronics Using Printing Methods Proceedings of the IEEE 93 7 1321 1329 doi 10 1109 jproc 2005 850304 S2CID 27061013 a b de Gans B J et al 2004 Inkjet Printing of Polymers State of the Art and Future Developments Advanced Materials 16 3 203 doi 10 1002 adma 200300385 Subramanian V et al 2005 Progress Toward Development of All Printed RFID Tags Materials Processes and Devices Proceedings of the IEEE 93 7 1330 doi 10 1109 jproc 2005 850305 S2CID 8915461 a b S Holdcroft Advanced Materials 2001 13 1753 Arias A C et al 2004 All jet printed polymer thin film transistor active matrix backplanes Applied Physics Letters 85 15 3304 doi 10 1063 1 1801673 Sirringhaus H et al 2000 High Resolution Inkjet Printing of All Polymer Transistor Circuits Science 290 5499 2123 2126 doi 10 1126 science 290 5499 2123 PMID 11118142 V G Shah and D B Wallace IMAPS Conference Long Beach 2004 a b c Bock K et al 2005 Polymer Electronics Systems Polytronics Proceedings of the IEEE 93 8 1400 1406 doi 10 1109 jproc 2005 851513 S2CID 23177369 Bao Z et al 1997 High Performance Plastic Transistors Fabricated by Printing Techniques Chemistry of Materials 9 6 1299 1301 doi 10 1021 cm9701163 a b Shaheen S E et al 2001 Fabrication of bulk heterojunction plastic solar cells by screen printing Applied Physics Letters 79 18 2996 doi 10 1063 1 1413501 M Renn US Patent number 7 485 345 B2 Page 3 J H Cho et al Nature Materials 19 October 2008 B Kahn Organic and Printed Electronics Volume 1 Issue 2 2007 B H King et al Photovoltaic Specialists Conference PVSC 2009 34th IEEE Fisher Christine Warmack Bruce J Yu Yongchao Skolrood Lydia N Li Kai Joshi Pooran C Saito Tomonori Aytug Tolga 2021 04 19 All aerosol jet printed highly sensitive and selective polyaniline based ammonia sensors a route toward low cost low power gas detection Journal of Materials Science 56 22 12596 12606 doi 10 1007 s10853 021 06080 0 ISSN 1573 4803 S2CID 233303736 Ingo Grunwald et al 2010 Biofabrication 2 014106 Chen Yi Dan Nagarajan Vijayasarathi Rosen David W Yu Wenwei Huang Shao Ying Oct 2020 Wireless Power Transfer via Strongly Coupled Magnetic Resonances Journal of Manufacturing Processes 58 55 66 doi 10 1016 j jmapro 2020 07 064 Gate B D et al 2005 New Approaches to Nanofabrication Molding Printing and Other Techniques Chemical Reviews 105 4 1171 96 doi 10 1021 cr030076o PMID 15826012 Li D Guo L J 2006 Micron scale organic thin film transistors with conducting polymer electrodes patterned by polymer inking and stamping PDF Applied Physics Letters 88 6 063513 doi 10 1063 1 2168669 hdl 2027 42 87779 Leising G et al 2006 Nanoimprinted devices for integrated organic electronics Microelectronics Engineering 83 4 9 831 doi 10 1016 j mee 2006 01 241 Knobloch A et al 2004 Fully printed integrated circuits from solution processable polymers Journal of Applied Physics 96 4 2286 doi 10 1063 1 1767291 Hines D R et al 2007 Transfer printing methods for the fabrication of flexible organic electronics 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10 1063 1 1609233 Aernouts T et al 2008 Polymer based organic solar cells using ink jet printed active layers Applied Physics Letters 92 3 033306 doi 10 1063 1 2833185 Ion Gel Insulator Archived from the original on November 14 2011 Harrey P M et al 2000 Interdigitated Capacitors by Offset Lithography Journal of Electronics Manufacturing 10 69 77 doi 10 1142 s096031310000006x Perelaer J et al 2006 Ink jet Printing and Microwave Sintering of Conductive Silver Tracks Advanced Materials 18 16 2101 2104 doi 10 1002 adma 200502422 Noh Y Y et al 2007 Downscaling of self aligned all printed polymer thin film transistors Nature Nanotechnology 2 12 784 789 doi 10 1038 nnano 2007 365 PMID 18654432 a b Mflex UK formerly Pelikon and elumin8 both in the UK Emirates Technical Innovation Centre in Dubai Schreiner in Germany and others are involved in EL displays Spectrolab already offers commercially flexible solar cells based on various inorganic compounds 1 Carey T Cacovich S Divitini G Ren J Mansouri A Kim J M amp Torrisi F 2017 Fully inkjet printed two dimensional material field effect heterojunctions for wearable and textile electronics Nature communications 8 1 1 11 https doi org 10 1038 s41467 017 01210 2 Tobjork Daniel Osterbacka Ronald 2011 03 23 Paper Electronics Advanced Materials 23 17 1935 1961 doi 10 1002 adma 201004692 ISSN 0935 9648 PMID 21433116 Grell Max Dincer Can Le Thao Lauri Alberto Nunez Bajo Estefania Kasimatis Michael Barandun Giandrin Maier Stefan A Cass Anthony E G 2018 11 09 Autocatalytic Metallization of Fabrics Using Si Ink for Biosensors Batteries and Energy Harvesting Advanced Functional Materials 29 1 1804798 doi 10 1002 adfm 201804798 ISSN 1616 301X PMC 7384005 PMID 32733177 Vicente Antonio T Araujo Andreia Gaspar Diana Santos Lidia Marques Ana C Mendes Manuel J Pereira Luis Martins Elvira Fortunato and Rodrigo 2017 02 22 Optoelectronics and Bio Devices on Paper Powered by Solar Cells IntechOpen ISBN 978 953 51 2936 3 GB 4681 Hanson Albert Printed Wires issued 1903 The printed circuit board is the base of modern electronics rostec ru Rostec November 24 2014 Archived from the original on August 28 2019 Retrieved November 28 2018 a b Jacobs John 2010 An Investigation of Fundamental Competencies for Printed Electronics Thesis Clemson University Printing Electronics Just National Geographic News National Geographic Partners LLC 10 May 2013 archived from the original on May 13 2013 retrieved November 30 2018 While You re Pp Print Me a Solar Cell MIT News MIT News Office retrieved November 30 2018 Stretchy solar cells a step closer Printed Electronics World IDTechEx 15 November 2018 retrieved November 30 2018 Zhang Chuck Printed Electronics Manufacturing Technologies and Applications PDF Georgia Tech retrieved November 30 2018 a b Das Raghu Printed Electronics Markets Technologies Trends PDF IDTechEx retrieved November 30 2018 New iPhones models support native background NFC tag read function Press release Thinfilm Retrieved November 30 2018 via IDTechEx Custom Printed Electronics Almax RP 30 December 2016 Retrieved 13 August 2021 Vicente Antonio T Araujo Andreia Mendes Manuel J Nunes Daniela Oliveira Maria J Sanchez Sobrado Olalla Ferreira Marta P Aguas Hugo Fortunato Elvira Martins Rodrigo 2018 03 29 Multifunctional cellulose paper for light harvesting and smart sensing applications Journal of Materials Chemistry C 6 13 3143 3181 doi 10 1039 C7TC05271E ISSN 2050 7534 Thinfilm and InkTec awarded IDTechEx Technical Development Manufacturing Award IDTechEx April 15th 2009 PolyIC ThinFilm announce pilot of volume printed plastic memories EETimes September 22nd 2009 All set for high volume production of printed memories Printed Electronics World April 12th 2010 Thin Film Electronics Plans to Provide Memory Everywhere Printed Electronics Now May 2010 IEEE P1620 Index page Archived from the original on 2011 06 10 Retrieved 2006 11 30 IEEE P1620 1 Index page Archived from the original on 2011 06 10 Retrieved 2006 11 30 iNEMI International Electronics Manufacturing Initiative www inemi org Further reading editPrinted Organic and Molecular Electronics edited by D Gamota P Brazis K Kalyanasundaram and J Zhang Kluwer Academic Publishers New York 2004 ISBN 1 4020 7707 6External links editCleaner Electronics Research Group Brunel University Printed Electronics conference exhibition Asia USA New Nano Silver Powder Enables Flexible Printed Circuits Ferro Corporation Western Michigan University s Center for Advancement of Printed Electronics CAPE includes AccuPress gravure printer Major Trends in Gravure Printed Electronics June 2010 Printed Electronics avistando el futuro Printed Electronics en Espanol Organic Solar Cells Theory and Practice Coursera Retrieved from https en wikipedia org w index php title Printed electronics amp oldid 1186574503, wikipedia, wiki, book, books, library,

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