Ribbon Ceramic, Novel Form Factor Enabling Product Applications

Ribbon Ceramic, Novel Form Factor Enabling Product Applications

John A. Olenick, ENrG Incorporated & Dr. Michael E. Badding, Corning

ENrG Incorporated, in 2015, and in collaboration with Corning Incorporated initiated a roll-to-roll (R2R) flexible ceramic development for its Zirconia Ribbon Ceramic product to address a variety of needs in Flexible Hybrid electronic (FHE) market applications. Flexible electronics require significant reductions in thickness, increased flexibility over smaller diameter rolls, and better durability and reliability for improved lifetimes under extreme conditions during manufacturing, and in operation. Zirconia Ribbon Ceramic (ZRC) is a highly flexible thin ceramic and proves to be an ultra-barrier for protecting moisture and air sensitive films, providing integration opportunities as a support, seal and/or multifunctional flexible circuit devices. ENrG, collaborating with ITN Energy Systems, proved high energy density, ultrathin solid-state lithium batteries integrated with solar power recharging were feasible. ZRC is both the support for the battery and solar power functions, and the outer package material, eliminating the need for other packaging, such as a coin cell, or pouch, resulting in thinner and lighter weight devices. Now a second material, Alumina Ribbon Ceramic is available for sampling within targeted FHE market applications. Ribbon Ceramic introduces a high-performance material in a new form factor, allowing the use of roll-to-roll processing in producing devices – methods previously never considered for ceramic coating or assembly. It also enables designers to conceive of new products, or new form factors for products, beyond traditional ceramic sheets. The presentation will show R2R processes demonstrated on less than 0.002” thick Ribbon Ceramic, and touch on the beginning of product concepts based on long lengths of thin, flexible ceramic. Applications addressed in this presentation will include solid-state batteries, SOFCs, LEDs, OLEDs, solar PV, sensors, heater circuits, and more. The author acknowledges cutting edge collaboration with the Corning Team, and the funded support of the FlexTech Alliance and NYSERDA.