Development of a high‐resolution RGBW flexible display using a white organic light‐emitting diode with microcavity structure and that of a side‐roll touch panel

In this study, white organic electroluminescent devices with microcavity structures were developed. A flexible high‐resolution active‐matrix organic light‐emitting diode display with low power consumption using red, green, blue, and white sub‐pixels formed by a color‐filter method was fabricated. In addition, a side‐roll touch display was developed in combination with a capacitive flexible touch screen.     

Development of flexible organic light‐emitting diode on barrier film and roll‐to‐roll manufacturing

To come out with a successful organic light‐emitting diode (OLED) lighting business, it is very important to have clear differentiation of OLED from LEDs. Flexible OLED has merits, such as capability to be mounted on the curved wall, which is not easy for LEDs to achieve the feature. There are several approaches to make flexible OLEDs especially among those plastic barrier films that can bring high level of flexibility, which could not be achieved by any conventional lighting method. In this paper, barrier films with various water vapor transmission rate values, including 10^{? 6} order, are applied, and the conditions to have almost no dark spot growth under 85 °C and 85% high temperature/humidity test are shown. Flexible OLED panels are manufactured with the world's first roll‐to‐roll equipment using plastic barrier film.     

Flexible hybrid substrates of roll‐to‐roll manufacturing for flexible display application

A flexible hybrid substrate was developed and demonstrated for roll‐to‐roll (R2R) manufacturing. Layer‐by‐layer misalignment can be well controlled within 5 µm. Top‐gate amorphous InGaZnO thin‐film transistor was fabricated on the flexible hybrid substrate by R2R process for the first time. A 4.3‐in. segment‐type reflective Electro‐Phoretic Display (EPD) display was also demonstrated to show the R2R capability of flexible substrates.     

Optical design and roll‐to‐roll fabrication process of microstructure film for wide viewing LCDs

We have developed a new microstructure film for wide viewing liquid crystal displays (LCDs). By attaching it to the surface of a conventional LCD, the viewing angle characteristics of LCD has drastically improved without causing a blur of the frontal image and a decrease in the contrast ratio under bright ambient light conditions. This film can be applied to various LC modes including twisted nematic and multidomain vertical alignment by changing its internal micrometer‐size 3D structure. Further, this film can be mass‐produced efficiently by self alignment roll‐to‐roll process.     

Optical filters for plasma‐display panels using organic dyes and conductive mesh layers by using a roll‐to‐roll etching process

Abstract— Optical filters with a high shielding capability against electromagnetic (EM) radiation for plasma‐display panels (PDPs) have been studied. We developed optical filters with high conductivity by utilizing a copper‐mesh layer, which was processed by using roll‐to‐roll photolithography and roll‐to‐roll etching. The copper‐mesh layer has a cross‐striped pattern with a surface resistance of 0.05Ω/□ and an opening ratio of approximately 93%. In combination with the copper‐mesh layer, organic dyes were applied to reduce the PDPs unfavorable emissions, such as near‐infrared light, and to control the transmission properties to improve the PDPs picture quality.     

Development of rollable silicon thin‐film‐transistor backplanes utilizing a roll‐to‐roll continuous lamination process

Abstract— Rollable silicon thin‐film‐transistor (TFT) backplanes utilizing a roll‐to‐roll process have been developed. The roll‐to‐roll TFT‐backplane technology is characterized by a glass‐etching TFT transfer process and a roll‐to‐roll continuous lamination process. The transfer process includes high‐rate, uniform glass‐etching to transfer TFT arrays fabricated on a glass substrate to a flexible plastic film. In the roll‐to‐roll process, thinned TFT‐glass sheets (0.1 mm) and a base‐film roll are continuously laminated using a permanent adhesive. Choosing both an appropriate elastic modulus for the adhesive and an appropriate tension strength to be used in the process is the key to suppressing deformation of the TFT‐backplane rolls caused by thermal stress. TFT backplanes that can be wound, without any major physical damage such as cracking, on a roll whose core diameter is approximately 300 mm have been sucessfully obtained. Incorporating the TFT‐backplane rolls into other roll components, such as color‐filter rolls, will make it possible to produce TFT‐LCDs in a fully roll‐to‐roll manufacturing process.     

Color displays and flexible displays using quick‐response liquid‐powder technology for electronic paper

Abstract— Color displays and flexible displays that use electronic liquid powder have been developed. Novel types of color displays using either a colored powder or a color filter are discussed. We have also developed a flexible display with low‐cost substrate films with a high‐throughput roll‐to‐roll manufacturing method. These technologies enable a QR‐LPD to be widely used as an electronic‐paper display.     

A Flexible electronic‐paper display with an ultra‐thin and flexible LSI driver using quick‐response liquid‐powder technology

Abstract— A thin and flexible LSI driver with a thickness of less than 35 μm for a passive‐matrix‐driven Quick‐Response Liquid‐Powder Display (QR‐LPD?) was successfully mounted onto the flexible printed circuit (FPC) and the back substrates of a flexible QR‐LPD?. Amounted LSI driver on a plastic substrate shows no significant degradation in the driving performances and maintains physical flexibility without any connection failures. This technology can realize a fully flexible electronic paper in combination with a plastic‐substrate QR‐LPD? fabricated by a roll‐to‐roll process.     

Large‐area black/white bistable cholesteric liquid‐crystal display and the thermal‐addressing system

Abstract— A 3‐m‐length black/white bistable cholesteric liquid‐crystal display was made by a roll‐to‐roll process and the display area is 25 × 300 cm. The black/white performance was made by black nano‐pigment and blended ChLC droplets with different wavelengths. It was written by a thermal‐addressing system, realizing high resolution and low cost.     

Roll‐to‐roll manufacturing of electronics on flexible substrates using self‐aligned imprint lithography (SAIL)

Abstract— The manufacture of large‐area arrays of thin‐film transistors on polymer substrates using roll‐to‐roll (R2R) processes exclusively is being developed. Self‐aligned imprint lithography (SAIL) enables the patterning and alignment of submicron‐sized features on meter‐scaled flexible substrates in the R2R environment. SAIL solves the problem of precision interlayer registry on a moving web by encoding all the geometry information required for the entire patterning steps into a monolithic three‐dimensional imprint with discrete thickness modulation. The pre‐aligned multiple‐step mask structure maintains its alignment regardless of subsequent substrate distortion. Challenges are encountered in relation to the novel nature of using flexible substrates and building toolsets for the R2R processing. In this paper, methods of the SAIL process, the resulting active‐matrix backplanes, the trajectory of SAIL process development, and the remaining issues for production are presented.     

Roll‐to‐roll manufacturing considerations for flexible,cholesteric liquid‐crystal display (Ch‐LCD) media

Abstract— Roll‐to‐roll methods and equipment to manufacture a bistable, passively driven display media on a flexible substrate have been developed. Using continuous coating techniques and equipment, cholesteric liquid‐crystal droplets in a gelatin binder and a dark layer are simultaneously coated onto laser‐etched‐patterned transparent ITO conductors on a polymeric web. Second conductors are printed with a UV‐curable polymer thick‐film ink over the active display layers, followed by slitting and chopping to complete the manufacture of display media in a full roll‐to‐roll mode. Segmented‐ and matrix‐display media can be generated using these techniques. This paper will focus on the manufacturing considerations for producing matrix‐display media.     

Organic wavelength‐converting‐film‐based hybrid planar white light‐emitting diodes

Abstract— In this study, organic wavelength‐converting films (WCFs) applied to InGaN blue LED‐based hybrid planar WLED has been fabricated. The organic dye layer in the WCF was formed between the upper and bottom polymer sheets by using a simple roll‐laminating technique. Subsequently, the hybrid planar WLEDs have been fabricated based upon these films. The luminous efficiency of green WCF‐based hybrid planar WLEDs with a single blue LED chip was 34.6 lm/W and that of red‐WCF‐assisted green WCF‐based hybrid planar WLEDs was 27.3 lm/W under 20 mA. The use of WCF to fabricate hybrid planar WLEDs showed better stability than that of directly coating organic color‐convergence materials (CCMs) on the LED chips. It only decreased to about 10% of the initial wavelength‐converting intensity after 1 hour of continual operation at 20 mA.     

High‐performance organic‐inorganic hybrid plastic substrate for flexible displays and electronics

Abstract— An inorganic‐dominated silica/polyimide (PI) hybrid film has been successfully developed for the fabrication of flexible AMOLEDs. The existence of networks between silica particles in the PI matrix have been confirmed by 3‐D tomography, respectively. The inorganic—organic hybrid film was achieved by roll‐type processing with a variety of attractive properties, such as low coefficient of thermal expansion (CTE, 20 ppm/°C), high transmittance (within the wavelength range of 400–700 nm), excellent flexibility, and high Young's modulus. Additionally, a flexible color‐filter, an AMEPD, and a flexible touch film were fabricated on hybrid film.     

Characterization of light extraction efficiency for WOLEDS with light‐out‐coupling layer

We studied the light extraction efficiencies of white organic light‐emitting diodes with a light‐out‐coupling layer by simulations and experiments. The light extraction efficiencies estimated by the simulation were confirmed to agree well with those measured by the experiments. Moreover, we successfully obtained the high light extraction efficiency (η_OC) of 69%.     

Organic light‐emitting diodes with enhanced out‐coupling efficiency using high‐refractive‐index glass frit

We have fabricated a novel type of substrate for organic light‐emitting diodes (OLEDs) to improve the light out‐coupling efficiency. It was fabricated by forming an excellent flat layer using a high‐refractive‐index B₂O₃‐SiO₂‐Bi₂O₃ frit glass on the light diffusive glass substrate. By using this substrate, we have sufficiently reduced the total internal reflection of OLEDs, and we successfully obtained more than 1.9 times higher light out‐coupling efficiency without spectral changes and viewing angle dependency. Furthermore, we have also successfully demonstrated 50 × 50 mm large‐area white OLEDs with this novel substrate.     

A rugged display: Recent results of flexible cholesteric liquid‐crystal displays

Abstract— A 3‐m‐long rugged flexible display having a novel single‐plastic‐substrate structure has been demonstrated with a coated cholesteric liquid‐crystal mixture. The display is designed to be fabricated by a roll‐to‐roll process to increase productivity at a competitive cost. It has the advantage of having almost no limitation in display length. The high‐resolution (300‐dpi) monochrome cholesteric liquid‐crystal display (ChLCD) can be achieved by using a photo‐addressing method. A single‐layered 10.4‐in. color ChLCD also has been developed with good color and contrast.     

Compact notch filter design using stepped impedance resonators for sharp roll‐off and large wideband rejection

This article presents the design of a compact notch filter with a sharp roll‐off and high rejection over a wideband. The filter comprises stepped impedance resonators that are interconnected to each other at strategic points on the resonator for optimal 3 dB roll‐off and high rejection over a wide stop‐band. The fabricated third‐order filter exhibits a steep 3 dB roll‐off and rejection exceeding 50 dB over the frequency range 2.70–6.19 GHz. © 2014 Wiley Periodicals, Inc. Int J RF and Microwave CAE 25:490–494, 2015.     

High‐performance white OLEDs with high color‐rendering index for next‐generation solid‐state lighting

Abstract— Several white‐OLED structures with a high color‐rendering index (CRI) were investigated for lighting applications. A two‐unit fluorescent/phosphorescent hybrid white OLED achieved an excellent CRI of 95, high luminous efficacy of 37 lm/W, and long lifetime of over 40,000 hours at 1000 cd/m². White‐OLED lighting panels of 8 × 8 cm for high‐luminance operation were fabricated, and a stable emission at 3000 cd/m² was confirmed. Quite a small variation in chromaticity in a different directions was achieved by using an optimized optical device structure. With a light‐outcoupling substrate, a higher efficacy of 56 lm/W, high CRI of 91, and longer half‐decay lifetime of over 150,000 hours at 1000 cd/m² was achieved. All‐phosphorescent white OLEDs placed on the light‐outcoupling substrate show a high CRI of 85 and higher efficacy of 65 lm/W with a fairly good half‐decay lifetime of over 30,000 hours. With a further voltage reduction and a high‐index spherical extractor, 128 lm/W at 1000 cd/m² has been achieved.     

Technologies toward flexible liquid‐crystal displays

Abstract— Several leading technologies for flexible liquid‐crystal displays have been developed recently at ERSO. The roll‐to‐roll compatible techniques, polymer‐added liquid crystal, have been applied on a film‐like substrate. A flexible black‐and‐white cholesteric liquid‐crystal display was also implemented by photo‐induced phase separation. Color filters placed on a plastic substrate by a low‐temperature manufacturing process was successfully fabricated. A novel design of a wide‐viewing‐angle color plastic LCD was also proposed.     

Flexible high‐resolution full‐color top‐emitting active‐matrix organic light‐emitting diode display

We developed a high‐performance 3.4‐in. flexible active‐matrix organic light‐emitting diode (AMOLED) display with remarkably high resolution using an oxide semiconductor in a backplane, by applying our transfer technology that utilizes metal separation layers. Using this panel, we also fabricated a prototype of a side‐roll display for mobile uses. In these AMOLED displays, a white OLED combined with a color filter was used in order to achieve remarkably high resolution. For the white OLED, a tandem structure in which a phosphorescent emission unit and a fluorescent emission unit are serially connected with an intermediate layer sandwiched between the emission units was employed. Furthermore, revolutionary technologies that enable a reduction in power consumption in both the phosphorescent and fluorescent emission units were introduced to the white tandem OLED.