10.3_Innovative High-Performance Deposition Technology for Low-Cost Manufacturing of OLED Lighting

Approximate Parameters
Gen 2 Baseline Gen 5 Future Glass Size 370x470 mm 1100x1300 mm Material usage 15-25% 60% TAC time 2-6 min 1-2 min Substrate Velocity 1.3-4 mm/sec 9-18 mm/sec Operating Time between loading 6 days 6 days Area of Good product 8,000-12,000 m2/year 190,000-380,000 m2/year Estimated Capital Cost of Whole line $50-100M (use $75M) $150-300M (use $200M) Depreciation per unit of production $600-1900/m2 $100-200/m2 Standard Assumptions:
• We work with many partners:
– Suppliers to the OLED lighting industry – Downstream luminaire partners.
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Innovative High-Performance Deposition Technology for Low-Cost Manufacturing of OLED Lighting
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DOE SSL Mfg Workshop 2014-05-07
Motivation – Whyቤተ መጻሕፍቲ ባይዱthis project is important
DOE SSL MYPP April 2014
TABLE 4.5 OLED PANEL AND LUMINAIRE MILESTONES
“Meeting the panel price goal of $200/klm by 2015, or soon thereafter, seems necessary in order to create a large enough demand to justify further investments in R&D and manufacturing capability. The luminaire price goal of $80/klm is appropriate for 2020 if OLEDs are to gain sufficient market penetration to contribute significantly to global energy savings.”
• We are the only US manufacturer of OLED lighting panels. • Founded in Rochester NY in 2010 • 22 full-time OLED experts
– Over 200 years of combined OLED experience – Experience across all areas of OLED technology
• •
Unfortunately we cannot show the design of our production machine or the design of the new vapor generation and depositions sources. However, we will describe the approach, considerations, and progress.
Sunic G5
80% uptime, 80% yield, 80% glass usage efficiency 5 year straight line depreciation
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Project Targets in Terms of Reference Machines
Cost and Price ($/m2)
Gaps between target price and predicted prices: • 2015 - ~3-5x • 2020 - ~4-5x We need innovation in equipment performance (cost, throughput, flexibility) to help reach the targets
– –
Sunic G2
•
Future system – G5 - 1100x1300mm
E.g. LG Chem, First O-Lite, COMMED This is the largest publicly disclosed production machine in use today (370x470mm)
Gen 2 Baseline Gen 5 Future Glass Size 370x470 mm 1100x1300 mm Material usage 15-25% 60% TAC time 2-6 min 1-2 min Substrate Velocity 1.3-4 mm/sec 9-18 mm/sec Operating Time between loading 6 days 6 days Area of Good product 8,000-12,000 m2/year 190,000-380,000 m2/year Estimated Capital Cost of Whole line $50-100M (use $75M) $150-300M (use $200M) Depreciation per unit of production $600-1900/m2 $100-200/m2
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• The goals of this deposition system are:
Reference Machines
• The most common OLED lighting system in production/pilot today is Sunic G2 – 370x470mm
•
The rough goals of the project are to design and build vapor generation and deposition sources to enable:
– – – – – Capital like G2 - $50-100M Material usage like G5 - ~60% Substrate speed like G5 – 9-18 mm/sec Depreciation like G5 - $100-200/m2 Easy on heat sensitive materials
• For our novel approach to vaporization, control, and distribution of organic vapor, the project encompasses:
– Design of the production-scale equipment of the deposition equipment, – Testing, analysis, and improvement of the equipment, – Implementation into production with demonstration 1. 2. 3. 4. Improve material usage efficiency Improve deposition rate – higher throughput Lead to lower capital cost OLED deposition machines Enable use of thermally sensitive materials
Innovative High-Performance Deposition Technology for Low-Cost Manufacturing of OLED Lighting Progress Review
John W. Hamer OLEDWorks LLC
2014-05-07
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OLEDWorks Introduction
• Built a state of the art OLED R&D lab • Designed and started-up a novel, flexible, scalable OLED production facility. • We have commercialized our first product.
With the current equipment, we do not hit the DOE milestones for industry success.
4x 4x 3,694 1,632 369 163 80
DOE SSL Mfg Workshop 2014-05-07
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Cost and Prices Relative to DOE Targets
DOE SSL Mfg Workshop 201405-07 6
Motivation – Why this project is important
Table 1-6 OLED Panel Cost Estimated Progress ($/m2) from Sept ‘13 DOE SSL Mfg Roadmap 2012 Integrated Substrate Organic Deposition Assembly and Test Overhead (incl labor) Total (unyielded) Yield of Good Product (%) Total Cost Deposition Machine Size TAC Time (min) Depreciation (at capacity, after yield) Total Cost with Depreciation Fraction of Total Cost due to Dep. Gross Margins Sales Price of Panels Price of light ($/klm at 10klm/m2) DOE Milestones (2014 DOE MYPP) Cost of Luminaire & Channel Costs Sales Price of Luminaire Price of light ($/klm at 10klm/m2) DOE Milestones (2014 DOE MYPP) 500 1,400 600 500 3,000 15% 20,000 G2 6 10,257 30,257 34% 50% 60,514 6,051 2013 250 600 350 300 1,500 25% 6,000 G2 6 6,154 12,154 51% 50% 24,308 2,431 2016 2020 2025 40 70 50 20 180 75% 240 G5 2 222 462 48% 50% 923 92 20 30 20 10 80 80% 100 G5 1 104 204 51% 50% 408 41 150 250 200 100 700 70% 1,000 G2 2 733 1,733 42% 50% 3,465 347 200 in FY15 4x 4x 4x 242,055 97,233 13,861 24,206 9,723 1,386