Flexible space for electronic device development

Published: 30-Nov--0001

Moving at breath-taking pace, the development of new video, DVD and LCD technology requires high tech, but flexible research facilities. Cleanroom Solutions describes how it achieved its latest electronics facility build.


When Sharp Laboratories of Europe, a subsidiary of Sharp Corporation of Japan, had a requirement for a multi-function cleanroom for its research and development operations at the Oxford Science Park, in the UK, the project was taken up by Brighton-based Cleanroom Solutions.

Sharp develops technology for new consumer electronic products to be sold around the world. The company is well known for its liquid crystal display research, including 3D displays, and its opto-electronic research on lasers. Cleanroom Solutions designed a class 6 to ISO 14644-1 (class 1,000 US Federal standard 209e) cleanroom with localised class 4 (class 10) workstations. The general areas were designed using equally spaced ceiling mounted HEPA filter units fed from the air conditioning system. Return air was taken at low level using return air ducts built into the cleanroom wall system. The ducts were spaced to minimise "dead" areas within the rooms.

Laminar flow canopies A range of vertical laminar flow canopies were fitted around the periphery of the room to give a flexible approach for the location of process equipment. These canopies were designed to take air from the rooms and pass it through secondary HEPA filters to provide a class 4 (class 10) environment at these positions. All canopies were acoustically lined to minimise noise levels within this research and development environment. Each canopy was individually switched to maintain the flexible nature of the complex. There was a requirement to provide chemical process benches to handle acid- and solvent-based processes. Cleanroom Solutions custom-designed and built a range of wet process benches according to Sharp's requirements. The acid benches are manufactured from fire retardant polypropylene and include various sinks, process gases, DI water taps and spray guns. The benches were equipped with electrical power points and specially designed pull-out storage bays. The solvent benches were manufactured completely from stainless steel and included all the necessary process tanks, gases and built-in process equipment. A special feature of these benches was the fire detection and suppression system that Sharp required for the flammable fluids. The system utilises ultra violet detectors above and below the worktops. Discharge heads were fitted within the benches and connected to CO2 gas bottles located in the service chase. The benches are designed as "low extract" to minimise the quantity of conditioned air that is extracted, thus saving on size of fans, extract ducts and running costs for the air conditioning. Acid fumes were run through PVC ducts and solvent fumes were run in stainless steel ducts to a point above the building and terminated in high velocity discharge ducts. Ducts and services were run to the benches in specifically designed service chases located outside the cleanroom. This allowed the majority of piped and electrical services to be run outside the clean environment and enables some of the servicing to be carried out outside of the cleanroom, minimising contamination. The air conditioning was designed to cope with maximum fore-seeable heat gains, as well as temperature and relative humidity constraints. The air change rates were in excess of the requirements stipulated to meet cleanroom standards because the critical factor became the air change required to dissipate process heat gains. The facility therefore works at a higher cleanroom standard. The areas were designed to meet local authority requirements for fire rating and emergency accesses. This was achieved by consultation and using fire rated materials for the walls. Glass vision panels were double-glazed, clear, fire-rated and incorporated window blinds to provide security during sensitive operations. The Oxford research centre has developed world leading processes, including: • Room temperature continuous wave (CW) operation of violet laser diodes fabricated by molecular beam epitaxy (MBE). The devices are being developed to comply with Blu-ray standard for the next generation DVD storage and video applications. In January 2004, scientists at Sharp were the first in the world to demonstrate violet lasers based on nitride semiconductors, grown using the MBE technique. • New LCD, which can simultaneously display different information and image content in right and left views in a single unit. By directionally controlling the viewing angle of the LCD, it possible to provide information and content tailored to specific users depending on the angle at which they view the screen. • New LCD process, which enables the LCD to be switched between a wide viewing angle and narrow viewing angle by means of an electrical ON/OFF switching action. This will allow people to view email and other private information on portable devices such as mobile phones and notebook PCs without having to worry about others in the vicinity being able to see what is being displayed on the LCD screen. The whole project was carried out to Construction (Design and Management) regulation and the facility remained operational during the build works. Cleanroom Solutions worked closely with Sharp to minimise the disruption caused during office hours and during sensitive experiments. The more noisy and vibration- generating operations were undertaken "out of hours". The project was completed on time and on budget. Mike Cherril, facilities manager for Sharp commented: "We chose Cleanroom Solutions because of its work for us in the past and it has delivered another excellent facility".

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