By Tom Cheyney, Small Times Senior Contributing Editor
 (Photo: TFE) |
Apr. 24, 2007 — Six months after electing a new board and revising its operational plan, Thin Film Electronics (TFE) has signed separate agreements with Xaar and Soligie to jointly develop low-cost volume production processes for its nonvolatile printed polymer memory technology. Product applications employing flexible memory could include smart labeling and packaging, game cards, RFID tags, and medical devices.
Under the terms of the respective deals, UK-based Xaar will produce samples at its development and manufacturing site in Järfällä, Sweden, while Soligie (owned by Taylor Corp.) will begin work on TFE’s memory products in its new 18,000-sq-ft cleanroom-equipped facility in the Minneapolis/St. Paul suburb of Savage.
“Depending on the application, different resolutions and registrations may be needed,” explains Johan Carlson, CEO of TFE. “Xaar, being in the business of producing inkjet heads, will help us demonstrate that inkjet can be used for manufacturing. Soligie will use other production methods (think newspaper presses) to bring memory production to volumes.”
Soligie president Matt Timm says they expect to “have [TFE] prototypes available in fall 2007, with volume processes becoming available in the second quarter of 2008,” which corresponds with the timeline provided by Carlson.
“Initial work will begin with prototyping equipment and subsequent processes will be developed on our production line,” says Timm. “The processes that we qualify for the TFE work will be driven by device architectures, material properties, and order volumes. We are not committed to, or constrained by, any one particular printing technique,” noting Soligie’s access to many kinds of techniques by virtue of its connection to Taylor’s family of print industry-related companies.
“Xaar is interested in showing the ability of inkjet printing in printed electronics in general — and together with TFE [we were] able to produce the first fully inkjet-printed memory devices [last year],” says Werner Zapka, head of Xaar’s advanced applications technology group. “The key challenges are to formulate an inkjetable fluid from TFE’s proprietary functional material and to produce high-quality surface morphology at the interfaces between the individual layers.”
The companies remain tight lipped about the specifics of many process and manufacturing capabilities. Timm says Soligie’s processes are “aimed to be as close to traditional printing as possible, but also contain steps that resemble electronics or semiconductor manufacturing.” He adds that the facility will likely employ roll-to-roll (R2R) processing for TFE’s products.
He explains that “it is too early to speculate on the maximum [memory] density” and that “substrate size is a variable, and we do not yet have data with respect to the maximum substrate size that can successfully yield good product.” Timms believes that with Soligie’s scaleable, high-volume R2R line, daily output in “excess of 1 million devices is entirely possible,” once the process and materials sets are dialed in.
Carlson describes the first TFE memories, which will be “physically contacted,” as “consisting of a printed bottom and top electrode sandwiching our ferroelectric nonvolatile rewritable polymer.” While the composition of the polymer remains proprietary, he disclosed that the material has a film thickness of 200 nm, a surface roughness average of < 1 nm, an electrode linewidth of 200 microns, and a 2 sq cm "footprint." He adds that the memory technology has demonstrated ultimate scalability "beyond 32 nm."
“Printable memory will be essential to the whole printable electronics effort—you can’t have a new paradigm in electronics without memory being a part of it,” says Lawrence Gasman of NanoMarkets. “The TFE/Xaar/Soligie alliance seems to be closer than anyone else in providing that missing piece of the equation. Of course, there will be challenges in actually getting this new memory commercialized, and it will be interesting to see if anyone else comes up with something competitive.”