Non-chemical low-cost patterning of flexible substrates and foils
Abstract
A Swedish research institute has developed a method for dry phase patterning (DPP) of single- or multilayer flexible substrates, all in one production step. The method replaces most etching processes and expands the possible product range due to its cold and dry process. The institute has large volume manufacturing capability and is looking for new products and customers.
Description
A wet chemistry etching process consists of several steps including for example deposition of photo resist, etch patterning of metal, removing the residuals of resist and etch liquids etc. The making of a pattern on a substrate by chemical etching may require up to 6-8 different process steps.
The Dry Phase Patterning (DPP) is a single step method for patterning metal or polymer layers on most flexible substrates. Examples of laminates patterned are: PEDOT/PE, Aluminum/Paper, Aluminum/PET, Copper/PET etc.
The material is patterned in one process step, unlike the etch process which requires several steps followed by removing the residuals of resist and etch liquids. In the DPP process, the residual product from the process is in a dry phase and is recyclable. Thus, the method has large environmental benefits, as no chemical products are used and the possibility of recycling the residual products. Pattern fibrous materials or products that is sensible 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 patterning has a high resolution; pattern with spacing smaller than 200µm has been proved. Components easily produced are all kind of passive components on flexible substrate, such as conductors, resistors, inductors and antennas. Patterning can be performed at speeds up to 150 m/min. The DPP resolution will not decrease with higher production speed.
Innovative Aspects:
The patterning process has properties which makes it interesting for low cost applications and its dry and cool process step makes it possible to pattern 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. Since no chemicals are used, the residual product is in a dry and easily recyclable phase. Besides, there is no need for destruction of hazardous wastes. High resolution at very high production speed makes it cost effective. Cold and dry makes it possible to pattern new materials.
