According to the company, the re-quired barrier performance and target device cost for each device are 10-2 to 10-3 g/m2/day at 7,000 yen/m2 for e-pa-per, 10-3 g/m2/day at 10,000 yen/m2 for flexible solar cells, and 10-4 g/m2/day at 100,000 yen/m2 for OLED. In contrast, conventional super high-barrier films have water vapor transmission rates in the 10-4 g/m2/day range using the com-pany's sputtering method with a com-posite compound, and in the 10-3 g/m2/day range with a single compound made by another company. Although they have good barrier performance, the cost was high compared to the re-quired device cost.Newly developed super high-barrier film38for encapsulation and pro-tection of flexible devices and or-ganic thin-film solar cells, which are expected to grow rapidly. Currently, super-high-barrier films deposited by sputtering or CVD methods are adopted, which can form high-density thin films, but their slow film formation speed and high cost limit their applications. On the other hand, barrier films formed by single-material vapor deposition can be formed at high speed. It is low-cost, but its applications are limited to food packaging mate-rials due to its barrier performance. Against this backdrop, Toray In-dustries, Inc., announced in April 2022 that it has developed super high barrier film that costs at least 80% less than conventional coun-terparts. The new film has the same level of barrier performance as su-per-high-barrier films made by the sputtering and CVD methods, and the deposition speed is more than 100 times faster than the general sputtering method and the cost is 1/5 of the conventional method. The company looks to commer-cialize the film in 2023 for high barrier performance applications, targeting flexible devices and or-ganic thin-film solar cell encapsu-lation, as well as food packaging materials that can contribute to re-ducing food loss.Toray Industries, Inc.Deposition speed and costAt the beginning of the press confer-ence, Mr. Shunichi Osada, Director of the Film Research Institute, explained the background behind the develop-ment of this super high-barrier film: "Recently, with the rapid development of IoT technology to build a smart soci-ety, the demand for wearable biomet-ric sensors and flexible displays is ex-pected to grow even larger. In addition, the global trend toward achieving car-bon neutrality is drawing attention to renewable energy and energy harvest-ing, and demand for organic thin-film solar cells and perovskite solar cells is also expected to grow. The organic devices and compounds used in these applications are vulnerable to moisture and need to be sealed and protect-ed. Super high-barrier films made by sputtering or CVD method have been used, but the slow deposition speed and high cost have made it difficult to expand their applications."Super-high barrier at level of aluminum foil or thin-film glass con-tributes to lower costThe super-high barrier film is the re-sult of applying the high-density com-pound film design technology cul-tivated through the development of Toray develops super-high barrier film with high deposition speed and offering dramatically lower costsHigh-barrier films are essential
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