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Ribbon Ceramic
Keywords: flexible, ceramic, Ribbon Ceramic
Flexible ceramics, a new material substrate for Flexible Hybrid Electronic applications, present new integration opportunities to product designers. Many product applications require better durability and reliability for improved lifetimes, whether under extreme conditions during manufacturing or in operation. Under continuing market pressure to shrink device profiles, Wearable and Mobile devices need to be lightweight, ultrathin, and conformable to the application footprint. High volume flexible electronics markets require better mechanical, thermal and reliability performance at elevated temperatures to withstand extreme conditions either during manufacturing, or while in operations. Often, a device’s profile is driven by the thickness of the packaging materials for batteries, or other components within. Flexible ceramics offer multi-functionality, such as being both a substrate and outer package material, leading to integration over assembly of components. ENrG’s Thin E-Strate®, a lightweight, thin ceramic is an ultra-barrier for protecting moisture and air sensitive films yet offers design opportunities as a support for flexible devices. In 2017, ENrG added roll-to-roll (R2R) flexible Zirconia Ribbon Ceramic to its Thin E-Strate® sheet products. The path to R2R first required production scaling the ceramic to half its thickness reaching 20 microns, and the development of both sheet and R2R laser cut processing of multiup imaged circuits. This presentation describes integration examples and the development of the support Ecosystem to enable flexible ceramics in product demonstrations including solid-state batteries, solar photovoltaics, flip-chipped LED flex circuit, OLEDs, sensors and flexible printed conductors. For these target product market opportunities, a R2R ceramic would be revolutionary by offering high temperature capable benefits for continuous coating processing and for flexibility in final products. This presentation describes the results to reduce the thickness of Thin E-Strate® to 20μm, demonstrate laser cutting smaller substrates from larger ceramic sheets and from ceramic ribbons of varying widths from 10-100mm by lengths as long as 30 meters, and illustrate product demonstrations including ITN Energy Systems solid-state batteries, University of Houston packaged LEDs, and Holst Center OLEDs. This talk will also touch upon the developing support Ecosystem for lamination, R2R coating and handling, along with laser singulation.
John A. Olenick, CEO & President
ENrG Incorporated
BUFFALO, NY
USA


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