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Short pulse laser amoled manufacturing

Development of 100 femtosecond laser based ultra-precision manufacturing process and system to increase production yield rate for next generation display "smart amoled (active matrix active matrix organic light emitting)" - flexible, foldable, transparent, wearable, and sensor integrated

Displays are key components of many of today’s mobile electronic devices such as smartphones, digital cameras, mp3 players, etc. As the market for mobile electronics expands, displays are required to fulfil more and more challenging requirements for power consumption, image quality and definition, as well as robustness. New technologies, such as flexible displays, make extensive use of Active Matrix Organic LEDs technology (AMOLED), and present significant manufacturing challenges. Due to the complexity and the multilayer structure of the displays (up to 20 different materials), units maycome out of the production line with defect, therefore decreasing productin yield. The presence of dead, over-bright pixels and other imperfections are considered unacceptable in such a high added-value consumer item. Current laser processing technologies face limitations such as the sensitivity of organic material to heating and the low thickness of thin film layers. Two hundred millions unit per year are manufactured in Samsung display only. The production yield is today less than 80%, leading to a loss of 400 Billions KRW (330 Millions Euro). The marget is currently growing at 200% per year, and most experts anticipate that the AMOLED market will reach 100 Trillions KRW ( 80 Billions €) per year in 2020. Because AMOLED consist of organic light emitting material which is vulnerable to thermal damage, traditional repair technology using laser, which can cause thermal effect, for LCD (Liquid Crystal Display) is impossible to apply to AMOLED repair. There is today no qualified ultra-precision laser processing (repair technology) for repairing failed pixels and defects on AMOLED. Yet, all commercialized AMOLED display products must exhibit zero defect. Femtosecond lasers enable very precise microprocessing without thermal effect, and have proven to be a very attractive technology for display repair. The machining precision can be significantly improved using femtosecond laser ablation as heat affected zone and debris generation is greatly reduced. In addition, non-thermal process is crucial for selective removal of multi-layer organic polymers that are susceptible to heat. However, to meet future challenges of AMOLED repair, it is expected that further improvement in the technology are needed. Current lasers have a pulse duration around 300 femtoseconds, and a reduction by a factor of three of the pulse duration could bring significant improvement in the manufacturing process. Therefore, theevelopment of a 100 femtosecond laser can be an essential key to avoid additional thermal damage for ultra-precision processing in OLED display as non-thermal laser process. From now on, demands of new concept of ultra-precision machining process and system using 100 femtosecond laser for Flexible, Foldable, Transparent, Wearable, and Sensor integrated Smart AMOLED display device will grow rapidly. Henceforward, approximately 5,000 sets of 100 fs laser ultra-precision laser machining system in display equipment market will be needed in the world near future (expected 5 billion USD in the display equipment of world market, Ref. Display Bank 2014). Additionally, Samsung focus on the smart AMOLED (Flexible, Foldable, Transparent, Wearable, and Sensor integrated) applications, and it will be in display market within 5 years from now. Certain of their efforts is presented for smart phone which model name are the Galaxy Note 4 Edge and Galaxy S6. And there is no laser technique which can be used in the field of smart AMOLED, yet. In order to increase the production yield rate of Smart AMOLED manufacturing, the goal of this project is set as shown below: - Development of 100 femtosecond laser for Smart AMOLED manufacturing - Development of 100fs laser based ultra precision manufacturing system with low loss, low dispersion, and high resolution - Development of 100fs laser based ultra precision non-thermal processing ; machining resolution : 50nm, machining roughness : 30 nm - Development of simulation tool and optical design of 100 fs based optical components and optical beam delivery devices in ultra precision manufacturing system SAMSUNG Display Co. Ltd. will evaluate the results of developed ultra-precision process and manufacturing system as a potential customer
Acronym: 
SHAMAN
Project ID: 
9 909
Start date: 
01-07-2015
Project Duration: 
36months
Project costs: 
2 400 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.