The breakthrough of flexible organic electronics and especially organic photovoltaics is highly dependent on cost-efficient production technologies. Roll-2-Roll processes show potential for a promising solution in terms of high throughput and low-cost production of thin film organic components. Solution based material deposition and integrated laser patterning processes offer new possibilities for versatile production lines. The use of flexible polymeric infstrates brings along challenges in laser patterning which have to be overcome. One main challenge when patterning transparent conductive layers on polymeric infstrates are material bulges at the edges of the ablated area. Bulges can lead to short circuits in the layer system leading to device failure. Therefore following layers have to have a sufficient thickness to cover and smooth the ridge. In order to minimize the bulging height, a study has been carried out on transparent conductive ITO layers on flexible PET in fstrates. Ablation results using different beam shapes, such as Gaussian beam, Top-Hat beam and Donut-shaped beam, as well as multi-pass scribing and double-pulsed ablation are compared. Furthermore, lab scale methods for cleaning the patterned layer and eliminating bulges are contrasted to the use of additional water based sacrificial layers in order to obtain an alternative procedure suitable for large scale Roll-2-Roll manufacturing. Besides progress in research, ongoing transfer of laser processes into a Roll-2-Roll demonstrator is illustrated. By using fixed optical elements in combination with a galvanometric scanner, scribing, variable patterning and edge deletion can be performed individually
A focused femtosecond laser beam was scanned across a nickel electrode in a line pattern with different line distances to generate a large electrochemical surface area for charge storage. During the laser structuring process, small metal particles were generated and sintered to a porous foam‐like structure, the so‐called laser‐induced nano‐foam (LINF), which strongly adheres to the substrate surface. The structuring was carried out in argon atmosphere, in order to prevent oxidation of the LINF structure during the structuring process. The topography of the LINF was investigated by scanning electron microscopy and laser scanning microscopy. The electrochemical surface area of the electrodes was determined by cyclic voltammetry based on the charging of the double‐layer. The total capacity of the nickel LINF electrodes was measured by galvanostatic charge‐discharge to test their capability for supercapacitor applications. The surface area enlargement and therefore the total capacity increases with decreasing line distance. The LINF structure provides a surface area enlargement up to a factor of 1600 and a total capacity up to 2 C cm−2.
The development of a millimeter-wave transparent antenna integrated inside a headlamp for automotive radar application is presented. The antenna consists of two radiating elements: the primary and secondary ones. The primary antenna is the one that is fabricated on RF PCB material (e.g., patch, slot, sectoral horn) and connected directly to the transceiver chip, while the secondary antenna is made of optically transparent materials such as glass, but with a optical transparent electrically conductive coating, well known as transparent conductive oxide (TCO). This antenna is realized as a planar offset reflector to collimate and shape the incoming wave from the primary antenna. This reflector is designed based on the Fresnel theory and the reflectarray concept. The division of the primary and secondary antenna enables the placement of the radar module (that contains the primary antenna) at the base of the headlamp, and therefore it is concealed from the surroundings and hidden from the optical path of the light. The secondary antenna is inserted in the space between the headlamp cover and the light unit. The main challenge here is to provide a maximum on transparency in the visible range of the spectrum with a specially designed and laser-based generated microstructure for the resonant reflection of the radar wavelength. An antenna demonstrator has been fabricated, and together with the headlamp cover, the radiation pattern and realized gain are measured. We reported here the measurement results for several reflector designs and concluded that the headlamp cover gives minimal influence on the antenna performance.
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