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Summary

A Swedish research institute has developed a method for dry phase patterning (DPP) of single- or multilayer flexible substrates, all in one production step. This low cost and environmentally friendly method can replace most etching processes, and expands the possible product range due to its cold and dry process. The institute has large volume manufacturing capability, technical collaboration as well as manufacturing agreements are both possible ways of collaboration.

Full description

The Dry Phase Patterning (DPP) is a single step method for patterning metal or polymer layers on top of most flexible substrates. Examples of laminates patterned are: PEDOT/PE, Aluminum/Paper, Aluminum/PET, Copper/PET etc.

The material is patterned in one single process step, unlike in a wet chemistry etch process, which may require up to 6-8 different steps. In the DPP process, the residual product is in a dry phase, contains no chemical products and it is recyclable. Thus, the method has large environmental benefits. Patterning of fibrous materials or products sensitive for fluids or chemicals has earlier been a problem. With the DPP method it is now possible to realize such products to a reasonable cost.

The DPP process has a high resolution; patterns with spacing smaller than 200 µm has been proved. Components easily produced are all kind of passive components on flexible substrate, such as conductors, resistors, inductors and antennas. Various sensor applications, as well as heating elements, are further examples of devices where the technology has been successful. Patterning can be performed at speeds up to 150 m/min. The resolution will not decrease with higher production speed.

Innovative Aspects

The DPP process has properties interesting for low cost applications, and its dry and cool process step enables patterning of materials sensitive to heat and liquids. Furthermore, the absence of chemicals in the process makes the products totally free from process chemical residuals.

One of the main benefits of the DPP method is the reduced environmental load. This is mainly due to reduced energy consumption; no chemicals, no washing, brushing or drying is necessary. The residual product is in a dry and easily recyclable phase, and there is no need for destruction of hazardous wastes.

High resolution at very high production speed makes the process very cost effective.

Partner expertise sought:

- Type of partner sought: Industry

- Specific area of activity of the partner: Electronics or electrical

- Task to be performed by the partner sought: manufacturing agreement based on absolutely novel process; testing and adaptation to specific needs.