Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies

Marja K. Välimäki; Laura I. Sokka; Heidi B. Peltola; Sami S. Ihme; Teijo M.J. Rokkonen; Timo J. Kurkela; Jyrki T. Ollila; Arttu T. Korhonen; Jukka T. Hast

doi:10.1007/s00170-020-06029-8

Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies

Marja K. Välimäki (Corresponding Author), Laura I. Sokka, Heidi B. Peltola, Sami S. Ihme, Teijo M.J. Rokkonen, Timo J. Kurkela, Jyrki T. Ollila, Arttu T. Korhonen, Jukka T. Hast

Research output: Contribution to journal › Article › Scientific › peer-review

33 Citations (Scopus)

Abstract

Printed and hybrid integrated electronics produced from recycled and renewable materials can reduce the depletion of limited material resources while obtaining energy savings in small electronic applications and their energy storage. In this work, bio-based poly(lactic acid) (PLA) and recycled polyethylene terephthalate (rPET) were fabricated in film extrusion process and utilized as a substrate in ultra-thin organic photovoltaics (OPV). In the device structure, metals and metal oxides were replaced by printing PEDOT:PSS, carbon and amino acid/heterocycles. Scalable, energy-efficient fabrication of solar cells resulted in efficiencies up to 6.9% under indoor light. Furthermore, virgin-PET was replaced with PLA and rPET in printed and hybrid integrated electronics where surface-mount devices (SMD) were die-bonded onto silver-printed PLA and virgin-PET films to prepare LED foils followed by an overmoulding process using the rPET and PLA. As a result, higher relative adhesion of PLA-PLA interface was obtained in comparison with rPET-PET interface. The obtained results are encouraging from the point of utilization of scalable manufacturing technologies and natural/recycled materials in printed and hybrid integrated electronics. Assessment showed a considerable decrease in carbon footprint, about 10–85%, mainly achieved through replacing of silver, virgin-PET and modifying solar cell structure. In outdoor light, the materials with low carbon footprint can decrease energy payback times (EPBT) from ca. 250 days to under 10 days. In indoor energy harvesting, it is possible to achieve EPBT of less than 1 year. The structures produced and studied herein have a high potential of providing sustainable energy solutions for example in IoT-related technologies.

Original language	English
Pages (from-to)	325–339
Journal	International Journal of Advanced Manufacturing Technology
Volume	111
DOIs	https://doi.org/10.1007/s00170-020-06029-8
Publication status	Published - Nov 2020
MoE publication type	A1 Journal article-refereed

Keywords

Climate impacts
Life cycle assessment
Poly(lactic acid)
Printed electronics manufacturing
Printed solar cells
Recycled PET

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1007/s00170-020-06029-8

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Välimäki, M. K., Sokka, L. I., Peltola, H. B., Ihme, S. S., Rokkonen, T. M. J., Kurkela, T. J., Ollila, J. T., Korhonen, A. T., & Hast, J. T. (2020). Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies. International Journal of Advanced Manufacturing Technology, 111, 325–339. https://doi.org/10.1007/s00170-020-06029-8

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title = "Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies",

abstract = "Printed and hybrid integrated electronics produced from recycled and renewable materials can reduce the depletion of limited material resources while obtaining energy savings in small electronic applications and their energy storage. In this work, bio-based poly(lactic acid) (PLA) and recycled polyethylene terephthalate (rPET) were fabricated in film extrusion process and utilized as a substrate in ultra-thin organic photovoltaics (OPV). In the device structure, metals and metal oxides were replaced by printing PEDOT:PSS, carbon and amino acid/heterocycles. Scalable, energy-efficient fabrication of solar cells resulted in efficiencies up to 6.9% under indoor light. Furthermore, virgin-PET was replaced with PLA and rPET in printed and hybrid integrated electronics where surface-mount devices (SMD) were die-bonded onto silver-printed PLA and virgin-PET films to prepare LED foils followed by an overmoulding process using the rPET and PLA. As a result, higher relative adhesion of PLA-PLA interface was obtained in comparison with rPET-PET interface. The obtained results are encouraging from the point of utilization of scalable manufacturing technologies and natural/recycled materials in printed and hybrid integrated electronics. Assessment showed a considerable decrease in carbon footprint, about 10–85%, mainly achieved through replacing of silver, virgin-PET and modifying solar cell structure. In outdoor light, the materials with low carbon footprint can decrease energy payback times (EPBT) from ca. 250 days to under 10 days. In indoor energy harvesting, it is possible to achieve EPBT of less than 1 year. The structures produced and studied herein have a high potential of providing sustainable energy solutions for example in IoT-related technologies.",

keywords = "Climate impacts, Life cycle assessment, Poly(lactic acid), Printed electronics manufacturing, Printed solar cells, Recycled PET",

author = "V{\"a}lim{\"a}ki, {Marja K.} and Sokka, {Laura I.} and Peltola, {Heidi B.} and Ihme, {Sami S.} and Rokkonen, {Teijo M.J.} and Kurkela, {Timo J.} and Ollila, {Jyrki T.} and Korhonen, {Arttu T.} and Hast, {Jukka T.}",

note = "Funding Information: The authors thank Tero Malm, Hannu Minkkinen and Timo Flyktman for the development work in film extrusion process; Anne Peltoniemi, Riikka Hedman and Antti Veijola for participating in the lab-scale preparation of OPVs and LED foils; Antti Veijola for the photographs; and Juha Linnekoski for providing information from PEF and Kofi Brobbey for providing valuable comments and language corrections. Part of the facilities used were provided by the Academy of Finland Research Infrastructure ?Printed Intelligence Infrastructure (PII-FIRI, grant no. 320020). The work is part of the Academy of Finland Flagship Programme, Photonics Research and Innovation (PREIN), decision 320168. VTT internal funding was used to finalize the manuscript. Funding Information: The authors thank Tero Malm, Hannu Minkkinen and Timo Flyktman for the development work in film extrusion process; Anne Peltoniemi, Riikka Hedman and Antti Veijola for participating in the lab-scale preparation of OPVs and LED foils; Antti Veijola for the photographs; and Juha Linnekoski for providing information from PEF and Kofi Brobbey for providing valuable comments and language corrections. Part of the facilities used were provided by the Academy of Finland Research Infrastructure “Printed Intelligence Infrastructure (PII-FIRI, grant no. 320020). The work is part of the Academy of Finland Flagship Programme, Photonics Research and Innovation (PREIN), decision 320168. VTT internal funding was used to finalize the manuscript. Publisher Copyright: {\textcopyright} 2020, The Author(s). Copyright: Copyright 2020 Elsevier B.V., All rights reserved.",

year = "2020",

month = nov,

doi = "10.1007/s00170-020-06029-8",

language = "English",

volume = "111",

pages = "325–339",

journal = "International Journal of Advanced Manufacturing Technology",

issn = "0268-3768",

publisher = "Springer",

}

Välimäki, MK, Sokka, LI, Peltola, HB, Ihme, SS, Rokkonen, TMJ , Kurkela, TJ , Ollila, JT, Korhonen, AT & Hast, JT 2020, 'Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies', International Journal of Advanced Manufacturing Technology, vol. 111, pp. 325–339. https://doi.org/10.1007/s00170-020-06029-8

Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies. / Välimäki, Marja K. (Corresponding Author); Sokka, Laura I.; Peltola, Heidi B. et al.
In: International Journal of Advanced Manufacturing Technology, Vol. 111, 11.2020, p. 325–339.

Research output: Contribution to journal › Article › Scientific › peer-review

TY - JOUR

T1 - Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies

AU - Välimäki, Marja K.

AU - Sokka, Laura I.

AU - Peltola, Heidi B.

AU - Ihme, Sami S.

AU - Rokkonen, Teijo M.J.

AU - Kurkela, Timo J.

AU - Ollila, Jyrki T.

AU - Korhonen, Arttu T.

AU - Hast, Jukka T.

N1 - Funding Information: The authors thank Tero Malm, Hannu Minkkinen and Timo Flyktman for the development work in film extrusion process; Anne Peltoniemi, Riikka Hedman and Antti Veijola for participating in the lab-scale preparation of OPVs and LED foils; Antti Veijola for the photographs; and Juha Linnekoski for providing information from PEF and Kofi Brobbey for providing valuable comments and language corrections. Part of the facilities used were provided by the Academy of Finland Research Infrastructure ?Printed Intelligence Infrastructure (PII-FIRI, grant no. 320020). The work is part of the Academy of Finland Flagship Programme, Photonics Research and Innovation (PREIN), decision 320168. VTT internal funding was used to finalize the manuscript. Funding Information: The authors thank Tero Malm, Hannu Minkkinen and Timo Flyktman for the development work in film extrusion process; Anne Peltoniemi, Riikka Hedman and Antti Veijola for participating in the lab-scale preparation of OPVs and LED foils; Antti Veijola for the photographs; and Juha Linnekoski for providing information from PEF and Kofi Brobbey for providing valuable comments and language corrections. Part of the facilities used were provided by the Academy of Finland Research Infrastructure “Printed Intelligence Infrastructure (PII-FIRI, grant no. 320020). The work is part of the Academy of Finland Flagship Programme, Photonics Research and Innovation (PREIN), decision 320168. VTT internal funding was used to finalize the manuscript. Publisher Copyright: © 2020, The Author(s). Copyright: Copyright 2020 Elsevier B.V., All rights reserved.

PY - 2020/11

Y1 - 2020/11

N2 - Printed and hybrid integrated electronics produced from recycled and renewable materials can reduce the depletion of limited material resources while obtaining energy savings in small electronic applications and their energy storage. In this work, bio-based poly(lactic acid) (PLA) and recycled polyethylene terephthalate (rPET) were fabricated in film extrusion process and utilized as a substrate in ultra-thin organic photovoltaics (OPV). In the device structure, metals and metal oxides were replaced by printing PEDOT:PSS, carbon and amino acid/heterocycles. Scalable, energy-efficient fabrication of solar cells resulted in efficiencies up to 6.9% under indoor light. Furthermore, virgin-PET was replaced with PLA and rPET in printed and hybrid integrated electronics where surface-mount devices (SMD) were die-bonded onto silver-printed PLA and virgin-PET films to prepare LED foils followed by an overmoulding process using the rPET and PLA. As a result, higher relative adhesion of PLA-PLA interface was obtained in comparison with rPET-PET interface. The obtained results are encouraging from the point of utilization of scalable manufacturing technologies and natural/recycled materials in printed and hybrid integrated electronics. Assessment showed a considerable decrease in carbon footprint, about 10–85%, mainly achieved through replacing of silver, virgin-PET and modifying solar cell structure. In outdoor light, the materials with low carbon footprint can decrease energy payback times (EPBT) from ca. 250 days to under 10 days. In indoor energy harvesting, it is possible to achieve EPBT of less than 1 year. The structures produced and studied herein have a high potential of providing sustainable energy solutions for example in IoT-related technologies.

AB - Printed and hybrid integrated electronics produced from recycled and renewable materials can reduce the depletion of limited material resources while obtaining energy savings in small electronic applications and their energy storage. In this work, bio-based poly(lactic acid) (PLA) and recycled polyethylene terephthalate (rPET) were fabricated in film extrusion process and utilized as a substrate in ultra-thin organic photovoltaics (OPV). In the device structure, metals and metal oxides were replaced by printing PEDOT:PSS, carbon and amino acid/heterocycles. Scalable, energy-efficient fabrication of solar cells resulted in efficiencies up to 6.9% under indoor light. Furthermore, virgin-PET was replaced with PLA and rPET in printed and hybrid integrated electronics where surface-mount devices (SMD) were die-bonded onto silver-printed PLA and virgin-PET films to prepare LED foils followed by an overmoulding process using the rPET and PLA. As a result, higher relative adhesion of PLA-PLA interface was obtained in comparison with rPET-PET interface. The obtained results are encouraging from the point of utilization of scalable manufacturing technologies and natural/recycled materials in printed and hybrid integrated electronics. Assessment showed a considerable decrease in carbon footprint, about 10–85%, mainly achieved through replacing of silver, virgin-PET and modifying solar cell structure. In outdoor light, the materials with low carbon footprint can decrease energy payback times (EPBT) from ca. 250 days to under 10 days. In indoor energy harvesting, it is possible to achieve EPBT of less than 1 year. The structures produced and studied herein have a high potential of providing sustainable energy solutions for example in IoT-related technologies.

KW - Climate impacts

KW - Life cycle assessment

KW - Poly(lactic acid)

KW - Printed electronics manufacturing

KW - Printed solar cells

KW - Recycled PET

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DO - 10.1007/s00170-020-06029-8

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SN - 0268-3768

VL - 111

SP - 325

EP - 339

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

ER -

Printed and hybrid integrated electronics using bio-based and recycled materials—increasing sustainability with greener materials and technologies

Abstract

Keywords

UN SDGs

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