Large Area Coatings

It has been understood for many years that the key factor in driving down the cost of thin film processes is strongly related to the substrate width or total area being processed per batch or per substrate. This has enabled tremendous cost reduction in the manufacturing of Flat Panel Displays, Solar Cells, and Roll-to-Roll polymers. For example, architectural glass coaters are now operating with substrates that are 3m x 6m in size.

However, this does not imply that scalability is without its own unique challenges. To operate at a high throughput, the process must be capable of depositing or etching at high rates. Additionally, the uniformity and film properties must be controlled over a large area as they are in a lab scale environment. This is true across all types of etching or for coatings whether they are used for optics, barriers, protection, or transparent conductors to name a few.

Along with the technical challenges, there are complex decisions that need to be made regarding Capital Expenditures (CapEx) versus Cost of Ownership (CoO). The facility requirements, substrate handling, and product yield are also key considerations.

The Large Area Coating Session is focused on the challenges related to scalability of thin film vacuum science. The talks may cover the limitations, challenges, or successes of moving from lab scale or pilot production up to high volume manufacturing (HVM).

Large Area Coatings TAC Chair: Ken Nauman, SCI/Bühler, knauman@sputteringcomponents.com; Assistant TAC Chairs: Marcus Frank, Bühler Group, marcus.frank@buhlergroup.com; Brent Boyce, Guardian Industries Corp., bboyce@guardian.com; Aneliia Wäckerlin, Glas Trösch AG; a.waeckerlin@glastroesch.ch; Kyle Schuberg, Gentex, kyle.schuberg@gentex.com