CPI have extensive capability to support the development and production of both organic light emitting diode (OLED) and organic photovoltaic (OPV) technologies. CPI offer a versatile equipment set to allow customers to scale up their products and processes from feasibility proof of concepts at small scale (100mm), through to cassette-cassette operation scale (GEN2 – 370x470mm).
In order to develop material sets, device designs and run proof of concept feasibility studies, CPI provide small scale (100-150mm substrate size) glove boxes with spin coating / evaporation technology to produce a range of device structures.
These systems focus on quick turnaround, proof of concept studies where the onus is on understanding the material characteristics, device structure, and electrical characteristics in a timely, efficient manner to speed up process development and aid troubleshooting. The systems are typically manually loaded by the operator and are situated in a Class 1000 clean room environment.
In order to scale up an optimised material set or device design, CPI offer the OLED/OPV prototyping line situated in a Class 100 clean room environment. Here the emphasis is on ensuring optimised manufacturing protocols. Substrates are transferred within dedicated processing cassettes with manual intervention kept to an absolute minimum. Clean room air is filtered to ensure a Class 100 environment. Minimising defectivity within an OLED/OPV structure is a pre-requisite in guaranteeing device yield as the technology scales up to larger substrate sizes. A typical OLED structure can consist of 8-10 layers with typical layer thicknesses of < 50nm.
To address the challenges faced in scaling up optoelectronics, CPI have installed a pilot production scale system. This system is dedicated to processing both air sensitive and non air sensitive material sets for the production of devices on substrates up to 200mm square. The system can accommodate the manufacture of both small molecule and solution based polymer materials and includes both slot die coating and spin coating technology. Evaporation technology provides both inorganic cathode capability and organic small molecule capability. Device performance and lifetime is enhanced by the use of a dedicated encapsulation
module to apply getters and glue adhesives. Fully automated robotic control, cassette to cassette handling and HEPA filtered laminar flow modules provide a unique environment to support high yield, low defect device quality.
To further support the optoelectronic platform in providing high yielding panels, CPI have recently completed the installation of a new pilot production scale activity. The high resolution wide area line has the ability to handle substrates of size 8 inch, 12 inch and GEN 2 scale (370mm x 470mm) The pilot line features sputter, dry etch, wet etch and cleaning capability and provides high quality panels for the Optoelectronics platform.
In Q2 2015, CPI will add additional flexibility with the installation of a 300mm web R2R coater for the printing of a range of organic material sets. The system will comprise of both slot die and screen printing capability, with options to upgrade to 500mm web width and to incorporate other printing techniques such as reverse gravure.
In addition, CPI will also install a complimentary encapsulation module. This will be configured to allow the roll of organic devices manufactured within the R2R coater to be processed through a lamination process using a barrier film thus providing protection to the device from water and/or oxygen ingress, both of which are known to be detrimental to device performance/lifetime. This will complement the existing batch capability at CPI.