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.     

A new pixel design and a novel driving scheme for multi‐domain vertically aligned LCDs

Abstract— By using a new pixel design and a novel driving scheme that adds a bias electrode and a bias TFT to the ordinary pixel structure, a high‐contrast‐ratio and wide‐viewing‐angle LCD mode, refered to as the biased vertical‐alignment (BVA) mode, has been sucessfully developed. Compared to the published data on the PVA and MVA modes, the BVA mode has a distinct advantage of lower manufacturing cost due to the elimination of a lithographic process step that forms either ITO cuts or protrusions on the color‐filter substrates. The BVA mode requires ITO cuts on the TFT substrate similar to that for the PVA and MVA modes. The 15‐in. BVA‐mode XGA prototype exhibits a high contrast ratio of 1200:1 and high cell transmittance of 4.3%.     

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.     

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.     

A novel quarter‐wave retardation film for improving viewing angle properties in time‐sequential stereoscopic 3D‐LCDs

We have successfully developed a quarter‐wave retardation film (QWF) for wide viewing angle 3D liquid crystal displays (3D‐LCDs) that provides high luminance, low crosstalk, low color change, and low head‐tilt‐angle dependency. It was found that the out‐of‐plane retardation (Rth) of the QWF in the LCD needs to be close to 0 nm in order to improve the 3D display properties at an off‐axis position and that the in‐plane retardation (Re) needs to be adjusted from 120 to 130 nm to achieve low color change with head tilting. We adopted a coating process for making our QWF because of its potential for retardation control. 3D‐LCDs with this QWF whose Rth was nearly zero had high performance and allowed off‐axis other than on‐axis.     

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.     

Novel photo‐aligned LC‐polymer compensation film for wide‐view TN displays

Abstract— We demonstrate a novel TN‐display compensation film with excellent contrast and minimal color shift, meeting the requirements for avionics displays. The film configuration was identified via extensive computer modeling. The experimental implementation based on ROLIC's LPP/LCP (linearly photopolymerizable polymer/liquid‐crystal polymer) technology results in excellent agreement with theoretical predictions.     

An overview of product issues in wide‐viewing TFT‐LCDs

Abstract— Several TFT‐LCD devices exhibiting high image quality have been developed and commercialized, overcoming the narrow viewing‐angle characteristics of conventional twisted‐nematic (TN) devices. Nevertheless, no single device dominates large‐sized TFT‐LCDs. In this paper, the product issues of existing LC devices related to manufacturing process and performance are discussed.     

Microcup® displays: Electronic paper by roll‐to‐roll manufacturing processes

Abstract— Rolls of flexible displays or electronic paper have recently been prepared by a high‐speed roll‐to‐roll manufacturing process based on SiPix's novel Microcup® and top‐sealing technologies. Both Microcup® electrophoretic displays (EPDs) and LCDs have been demonstrated. The display rolls are format flexible and may be cut into desirable size and shape for a variety of applications. High‐performance flexible passive‐matrix Microcup® EPDs having a wide range of threshold voltages have also been demonstrated.     

Moving‐picture response time (MPRT) of LCDs for the oblique viewing direction

Abstract— The dynamic performance of displays is an important characteristic for multimedia applications. Motion‐picture response time (MPRT) has been used as an indicator of the dynamic performance of LCDs. This paper describes a comprehensive method of MPRT evaluation for the oblique viewing direction. By using a tilted camera configuration, the angular dependency of MPRT is investigated for the condition that the horizontally scrolling patterns are observed from the vertical direction. For each gray‐to‐gray transition, distinct changes in MPRT and the luminance profile of blur are observed.     

LC GRIN lens mode with wide viewing angle for rotatable 2D/3D tablet

To widen the vertical and horizontal angular ranges where the lens performs well, the off‐axis performance of a liquid crystal gradient index (LC GRIN) lens is analyzed by the combined simulation system of an LC director simulator and a ray‐tracing simulator. We found that the angular difference between an LC alignment direction and an electrode array direction of the LC GRIN lens is one of significant parameters, and detailed conditions of structure are established. The measurement result shows that the developed structure reduces the degradation ratio in a luminance profile from 61% to 3.2%. We have applied a user tracking system for the rotatable 3D display, equipped with a detection of a panel orientation and a face position. As a result, we have developed a rotatable 2D/3D tablet whose 3D viewing azimuth angle is over 30° in both landscape and portrait orientations.     

Properties of column spacers on a flexible color filter using a roll‐to‐roll process

Abstract— Column spacers were manufactured by a roll‐to‐roll process for a flexible plastic substrate and an LCD prototype was demonstrated for the first time. The purpose of this paper is to obtain a stable cell gap for plastic LCDs by designing the column spacers. The optimum condition was derived for the properties of the column spacers parameters, such as the cross section, density, and hardness. As a result, we could determine the optimum elastic modulus of the column spacers needed in order to precisely maintain the cell gap of the LCD as well as that of conventional glass plates, resulting in a uniform display luminance.     

A viewing‐angle‐controllable blue‐phase liquid‐crystal display

Abstract— A viewing‐angle‐controllable liquid‐crystal display (LCD) is proposed. When the device is only driven by an in‐plane electric field, it exhibits a wide‐viewing‐angle (WVA) mode. And it exhibits narrow‐viewing‐angle (NVA) mode when it is driven by a vertical electric field as well as an in‐plane electric field. In this manner, the viewing angle of the device can be controlled from 100° to 30°. The device exhibits a good viewing‐angle‐controlling characteristic and high transmittance.     

Novel application of ink‐jet‐printing technology in multi‐domain alignment liquid‐crystal displays

Abstract— Based on the drop‐on‐demand characteristics of ink‐jet printing, the multi‐domain alignment liquid‐crystal display (LCD) could be achieved by using patterned polyimide materials. These polyimide ink locations with different alignment procedures could be defined in a single pixel, depending on the designer 's setting. In this paper, we combined the electro‐optical design, polyimide ink formulation, and ink‐jetting technology to demonstrate the application of multi‐domain alignment liquid‐crystal display manufactory. The first one was a multi‐domain vertical‐alignment LCD. After the horizontal alignment material pattern on the vertical alignment film, the viewing angle would reach 150° without compensation film. The second one was a single‐cell‐gap transflective LCD within integrating the horizontal alignment in the transmissive region and hybrid alignment in the reflective one in the same pixel. In addition, this transflective LCD was also demonstrated in the form of a 2.4‐in. 170‐ppi prototype.     

A single‐cell‐gap transflective liquid‐crystal display using different pretilt angles in transmissive and reflective regions

Abstract— A single‐cel l‐gap transflective liquid‐crystal display with two types of liquid‐crystal alignment based on an in‐plane‐switching structure is proposed. The transmissive region is almost homeotropically aligned with the rubbed surfaces at parallel directions while the reflective region has a homeotropic liquid‐crystal alignment. For every driving voltage for a positive‐dielectric‐anisotropy nematic liquid crystal, the effective cell‐retardation value in the transmissive region becomes larger than that in the reflective region because of optical compensation film which is generated by low‐pretilt‐angle liquid crystal in the transmissive region. Under the optimization of the liquid‐crystal cell and alignment used in the transmissive and reflective areas, the transmissive and reflective parts have similar gamma curves. An identical response time in both the transmissive and reflective regions and a desirable viewing angle for personal portable displays can also be obtained.     

A photographic technique for assessing the viewing‐angle performance of liquid‐crystal displays

Abstract— Liquid‐crystal displays (LCDs) have notable variation in luminance and perceived contrast as a function of the angle from which they are viewed. Though this is an important performance issue for LCDs, most evaluation techniques for assessing this variation have been limited to laboratory settings. This study demonstrates the use of a photographic technique for such an evaluation. The technique is based on an actively cooled charge‐coupled‐device (CCD) detector in combination with a macro lens covering a circular angular range (θ) of ±42.5°. The camera was used to evaluate the luminance and perceived contrast properties of an LCD. Uniform field images corresponding to 17 equally spaced gray‐scale values in the digital driving level (DDL) range of the display system were acquired. The 12‐bit gray‐scale digital images produced by the camera were converted to luminance units (cd/m²) via the measured luminance vs. DDL response function of the camera. The changes in perceived contrast as a function of viewing angle were derived from the Barten model of the gray‐scale response of the human‐visual system using the methods proposed by the AAPM TG18 Report. The results of this photographic technique were compared to measurements acquired from a similar display using a Fourier‐optics‐based luminance meter. The results of the two methods generally agreed to within 5%. The photographic methods used were found to be accurate and robust for in‐field assessment of the angular response of LCDs over the FOV of the camera.     

Objective evaluation of qualified viewing spaces for near‐to‐eye and autostereoscopic two‐view displays

Abstract— Virtual‐image (near‐to‐eye) and two‐view autostereoscopic (3‐D) displays share similar optical properties in the comfortable user position for viewing. In this paper, the definitions and criteria of qualified viewing space (QVS) and qualified stereoscopic viewing space (QSVS) are discussed. Due to the complex nature of these viewing spaces, the related presumptions and the required optical characteristics and their measurements are specified. The effects of different display and observer parameters, such as interpupillary distance, to the resulting viewing spaces are discussed. Finally, real measurement data of two autostereoscopic display devices are presented.     

Direct imaging exposure equipment with high overlay accuracy for flexible substrate in roll‐to‐roll method

In order to fabricate thin‐film transistors on a flexible substrate, it is required to overlay patterns with high alignment accuracy. A polymer film can be deformed greatly and easily through thin‐film transistor fabrication processes because the glass transition point of a polymer film is below the maximum temperature of the processes. Furthermore, low stiffness of a polymer film can cause deformation when the polymer film is loaded on a working holder. These matters make it difficult to make patterns directly on a polymer film with high alignment accuracy. We proposed three concepts that solve three technical issues in order to directly make patterns with high overlay accuracy on a flexible film without a support substrate. We developed roll‐to‐roll exposure equipment with high overlay accuracy for a flexible substrate. Using this equipment, we succeeded to directly make patterns on a PET film, achieving a resolution of less than 6‐μm line and space pattern and an overlay accuracy of less than ±5 μm.     

Roll‐to‐roll UV embossing process applied for light bar‐based sub‐wavelength gratings for backlight

This study proposes a roll‐to‐roll process‐based sub‐wavelength grating, which is attached on a light bar to turn the side‐lit red/green/blue (620, 520, and 450 nm) incident rays into a uniformly and normally output white light with high illuminance from the light bar's surface. On the basis of the rigorous coupling wave analysis, the relationship between the first‐order transmission/reflection efficiency and the pitch of the gratings with different shapes was analyzed. The optimal design can effectively reduce the coupling length and enhance the white color balance for display applications.     

Manufacture of organic transistors on large‐area flexible substrate using direct imaging exposure system by wet process suitable for roll‐to‐roll production

Organic thin‐film transistors (OTFTs) can be fabricated via a wet process and have exceptionally high flexibility. Therefore, production using the roll‐to‐roll (RtoR) method is expected. We succeeded in developing a new OTFT wet fabrication process adaptable to the RtoR process. Utilizing the electroless plating method for wiring formation, all materials can be formed in a wet process and can be patterned using the photolithography process. In addition, we succeeded in fabricating OTFT on an A4‐type flexible substrate using RtoR direct imaging exposure system.