Flexible ferroelectric liquid‐crystal devices containing fine polymer fibers

A new flexible ferroelectric liquid‐crystal‐display device with gray‐scale capability has been created by using submicrometer‐diameter polymer fibers. The polymer fibers, which are formed by photopolymerization of aligned monomer molecules in liquid crystal, align the ferroelectric liquid crystal and mechanically support two flexible thin plastic substrates. The composite film made of liquid crystal and polymer with a thickness of 2 μm was formed between the plastic substrates by using a fabrication method consisting of coating, lamination, and ultraviolet irradiation processes without the conventional gap‐forming and injection processes. The fabricated flexible device revealed gray‐scale capability due to the change in spatial distribution of micrometer‐sized binary‐switching liquid‐crystal domains. From the polarizing microscope observation, it was found that the switching domains are generated and expanded from the areas with poor polymer density. The experimental results indicated that the polymer fibers spatially modulate the threshold voltage for molecular switching. Our device exhibits great potential for flexible large‐sized light‐weight motion‐image displays.     

A 5‐in. flexible ferroelectric liquid‐crystal display driven by organic thin‐film transistors

Abstract— An organic thin‐film‐transistor (OTFT) driven color flexible ferroelectric‐liquid‐crystal (FLC) display with 160 × 120 pixels and a resolution of 50 ppi has been developed. The flexible FLC was fabricated on a pentacene‐OTFT array using printing and lamination techniques. To drive the display at a fast driving speed, an OTFT was developed with a short channel length having a large current output. The fabricated OTFT array with a channel length of 5 μm exhibits a carrier mobility of 0.3 cm²/V‐sec and an ON/OFF ratio of over 10⁷ at a low drain voltage of ?6 V. A field‐sequential‐color system with a flexible backlight unit was also developed and used to drive the display. Color moving images were successively shown on the 5‐in. display using an active‐matrix driving technique of the OTFT.     

Development of a color‐tunable polychromatic organic‐light‐emitting‐diode device for roll‐to‐roll manufacturing

A flexible vertically stacked flexible polychromatic color‐tunable OLED has been developed by means of low resistive intermediate electrode technology. The polychromatic OLED has a capability to show 16 million colors with 105% National Television Committee Standard (NTSC) color reproduction. The device can produce arbitrary shape with arbitrary colors, suitable for artistic expressions, just as many as those used in information displays. Independently controlled red, green, and blue light‐emitting layers are stacked vertically. With conventional indium tin oxide technology, because of the temperature restriction, it was quite difficult to achieve low resistance on plastic substrate. The reported numbers were all more than 80 Ω/□. According to the surface mobility control using Fick's law analysis, low sheet resistance 7.34 Ω/□ on plastic film was developed. At first, flexible 7.17 cm² transparent OLED was fabricated for the performance confirmation of transparent electrode. And then polychromatic color‐tunable OLED with the same size were successfully fabricated on plastic. With optical length optimization for each color stack of polychromatic OLED, more than 100% color reproduction in National Television Committee Standard was achieved by stack design. The polychromatic device can be used for colored illumination, as well as for organic‐light‐emitting display pixels for three times emission than conventional pixel design. The device is fabricated on plastic substrate so that the polychromatic organic‐light‐emitting‐diode device is manufacturable with roll‐to‐roll production line.     

Fabrication of flexible organic light‐emitting‐diode display with a flexible color filter driven by In—Ga—Zn—Oxide TFTs

Abstract— A novel flexible active‐matrix organic light‐emitting‐diode (OLED) display fabricated on planarized stainless—used‐steel substrates with a resolution of 85 dpi in a 4.7‐in. active area has been demonstrated. Amorphous indium—gallium—zinc—oxide thin‐film transistors were used as the backplane for the OLED display with high device performance, high electrical stability, and long lifetime. A full‐color moving image at a frame frequency of 60 Hz was also realized by using a flexible color filter directly patterned on a plastic substrate with a white OLED as the light source.     

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.     

Electron‐beam curing of color filters for flexible‐display applications

Abstract— Color filters spin‐coated on plastic and glass substrates have been cured by electron‐beam radiation instead of by the conventional thermal‐heating method. The electron‐beam curing of the color filters has many advantages over the thermal curing method. Electron‐beam curing is, in principle, a non‐thermal method where low‐temperature (<100°C) curing of color filters on plastic substrates can be realized for the manufacturing process of flexible display panels. A color‐filter resist having a 1.5‐μm thickness was spin‐coated on plastic (polycarbonate) and glass (corning 1737) substrates. The effect of the electron‐beam radiation conditions, such as electron‐beam energy (0.3–1.0 keV), radiation dosage (10–200 kGy), and ambient oxygen has been characterized. The degree of curing was analyzed by using the characteristic absorption peaks at 808 and 1405 cm^?1 in the FT‐IR spectrum. These two peaks originate from the carbon double bonds (>C=C<) of the multi‐functional acrylate monomer which exist in the color‐filter resist. By electron‐beam radiation, the spin‐coated color filter can be effectively polymerized at g (glass transition temperature) of the plastic substrates. The electron beam can solve the problems of the conventional thermal curing method, such as thermal deformation of a plastic substrate and difficulty in achieving dimensional control of a color‐filter pattern due to a large coefficient of thermal expansion (20–70 ppm/°C) compared to that of a glass 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.     

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.     

A 5.8‐in. phosphorescent color AMOLED display fabricated by ink‐jet printing on plastic substrate

Abstract— A flexible phosphorescent color active‐matrix organic light‐emitting‐diode (AMOLED) display on a plastic substrate has been fabricated. Phosphorescent polymer materials are used for the emitting layer, which is patterned using ink‐jet printing. A mixed solvent system with a high‐viscosity solvent is used for ink formulation to obtain jetting reliability. The effects of evaporation and the baking condition on the film profile and OLED performances were investigated. An organic thin‐film‐transistor (OTFT) backplane, fabricated using pentacene, is used to drive the OLEDs. The OTFT exhibited a current on/off ratio of 10⁶ and a mobility of 0.1 cm²/V‐sec. Color moving images were successfully shown on the fabricated 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.     

Development of 8‐in. oxide‐TFT‐driven flexible AMOLED display using high‐performance red phosphorescent OLED

An 8‐in. flexible active‐matrix organic light‐emitting diode (AMOLED) display driven by oxide thin‐film transistors (TFTs) has been developed. In‐Ga‐Zn‐O (IGZO)‐TFTs used as driving devices were fabricated directly on a plastic film at a low temperature below 200 °C. To form a SiO_x layer for use as the gate insulator of the TFTs, direct current pulse sputtering was used for the deposition at a low temperature. The fabricated TFT shows a good transfer characteristic and enough carrier mobility to drive OLED displays with Video Graphic Array pixels. A solution‐processable photo‐sensitive polymer was also used as a passivation layer of the TFTs. Furthermore, a high‐performance phosphorescent OLED was developed as a red‐light‐emitting device. Both lower power consumption and longer lifetime were achieved in the OLED, which used an efficient energy transfer from the host material to the guest material in the emission layer. By assembling these technologies, a flexible AMOLED display was fabricated on the plastic film. We obtained a clear and uniform moving color image on the display.     

Flexible color LCD panel driven by low‐voltage‐operation organic TFT

Abstract— A flexible color LCD panel driven by organic TFTs (OTFTs) was successfully demonstrated. A pentacene OTFT with an anodized Ta₂O₅ gate insulator, which can be operated at low voltage, was developed. In order to improve the electrical performance of the OTFT, the gate insulator was surface treated by processes such as O₂ plasma, UV light irradiation, and hexamethyldisilane treatments. The fabricated OTFT exhibited a mobility of 0.3 cm²/V‐sec and a current on/off ratio of 10⁷ with a low operating drain voltage of ?5 V. A fast‐response‐time flexible ferroelectric LCD, which contains polymer networks and walls, was integrated with the OTFTs by using a lamination and a printing technique. As a result, color images were achieved on the fabricated panel by using a field‐sequential‐color method at a low driving voltage of less than 15 V_pp.     

Dual‐plate OLED display (DOD) based on amorphous‐silicon (a‐Si) TFT backplane

Abstract— An improved AMOLED with an a‐Si TFT backplane based on a unique structure is reported. The new structure is refered to as a dual‐plate OLED display (DOD). While a top‐emission OLED array is directly fabricated on a TFT backplane, the DOD consists of an upper OLED substrate and a lower TFT substrate, which are independently fabricated. Because the OLED substrate, which is fabricated through the process flow of bottom emission, is attached to the TFT substrate, the light is emitted in the opposite direction to the TFT backplane. The DOD enables the design of large‐sized TFTs and a complicated pixel circuit. It can also not only achieve higher uniformity in luminance in large‐sized displays due to the low electrical resistance of the common electrode, but also wider viewing angles.     

Compact and power‐saving polysilicon data driver with common‐decoder DA converter (CD‐DAC)

Abstract— A common‐decoder architecture for a data‐driver circuit fabricated by using a polysilicon process has been developed. The architecture achieves a compact circuit and low‐power consumption. In application to an integrated polysilicon data driver for small‐sized displays, this architecture reduces the area of the data driver by removing the vertical bus lines that occupy a large area. It also suppresses the power consumption of the data bus by reducing the number of driven lines in the data bus during word‐to‐word transitions from six to two. By using a conventional 4‐μm design rule, we fabricated an active‐matrix OLED (AMOLED) panel with an integrated six‐bit data‐driver circuit with 384 outputs. The driver circuit had a height of 2.6 mm and a pitch between output lines of 84 μm. The maximum power consumption of the driver was only 5 mW, i.e., 3.8 mW for logic‐data transfer and 1.2 mW for reference‐voltage source. Furthermore, we also fabricated an active‐matrix LCD (AMLCD) panel including driver circuits of the same type as the integrated elements. Six‐bit full‐color images were successfully displayed on both panels.     

High‐mobility solution‐processed organic thin‐film transistor array for active‐matrix color liquid‐crystal displays

Abstract— A solution‐processed organic thin‐film‐transistor array to drive a 5‐in.‐diagonal liquid‐crystal display has been fabricated, where semiconductor films, a gate dielectric film, and passivation films have all been formed using solution processes. A field‐effect mobility of 1.6 cm²/V‐sec, which is among the highest for solution‐processed organic thin‐film transistors ever reported, was obtained. This result is due to semiconductor material with large‐grain‐sized pentacene crystals formed from a solution and adoption of three‐layered passivation films that minimize the performance degradation of organic thin‐film transistors.     

Fabrication of 5.8‐in. OTFT‐driven flexible color AMOLED display using dual protection scheme for organic semiconductor patterning

Abstract— A 5.8‐in. wide‐QQVGA flexible color active‐matrix organic light‐emitting‐diode (AMOLED) display consisting of organic thin‐film transistors (OTFTs) and phosphorescent OLEDs was fabricated on a plastic film. To reduce the operating voltage of the OTFTs, Ta₂O₅ with a high dielectric constant was employed as a gate insulator. Pentacene was used for the semiconductor layer of the OTFTs. This layer was patterned by photolithography and dry‐etched using a dual protection layer of poly p‐xylylene and SiO₂ film. Uniform transistor performance was achieved in the OTFT backplane with QQVGA pixels. The RGB emission layers of the pixels were formed by vacuum deposition of phosphorescent small molecules. The resulting display could clearly show color moving images even when it was bent and operated at a low driving voltage (below 15 V).     

New approaches to process simplification for large‐area high‐resolution TFT‐LCDs

Abstract— Novel process architectures are proposed for fabricating large‐area high‐resolution TFT‐LCDs with a minimal number of process steps. A low contact resistance between Al bus lines and the transparent conductive oxide layer, necessary for large‐area panels, is obtained by inducing a self‐formed inter‐metallic compound layer at the interface without using any additional buffer or capping layers. For enhanced brightness and resolution, a new TFT array structure integrated on a color‐filter substrate, referred to as an Array on Color Filter (AOC) structure, has been developed. Good‐quality TFTs were successfully constructed on the newly developed color filter for AOC within a sufficiently wide process margin. By adopting these novel technologies, a 15.0‐in. XGA prototype panel was fabricated and shows good display performance. Thus, these novel technologies have improved cost efficiency and productivity for TFT‐LCD manufacturing, and can be applied to the development of TFT‐LCDs of extended display area and enhanced resolution, benefiting from the low resistance bus lines, the high aperture ratio, and reduction in total process steps.     

Low‐temperature fabrication of 5‐in. QVGA flexible AMOLED display driven by OTFTs using olefin polymer as the gate insulator

Abstract— A 5‐in. QVGA flexible AMOLED display driven by OTFTs has been fabricated at a low temperature of 130°C. A polyethylene naphthalate film was used as the flexible substrate and an olefin polymer was used as the gate insulator for the OTFT. This layer was formed by spin‐coating and baking at 130°C. Pentacene was used as the organic semiconductor layer. The OTFT performance to drive the flexible display with QVGA pixels in terms of current on/off ratio, carrier mobility, and spatial uniformity on the backplane have been obtained. Phosphorescent and fluorescent OLEDs were used as light‐emitting devices on a flexible display. Those layers were formed by vacuum deposition. After the flexible display was fabricated, a clear and uniform moving image was obtained on the display. The display also showed a stable moving image even when it was bent.     

Fabrication of anti‐reflection coatings on plastics using the spraying layer‐by‐layer self‐assembly technique

Abstract— Anti‐reflection (AR) coatings on plastic substrates have been extensively investigated with the development of large‐area LCD and LED displays. A robust AR coating on plastics requires strong adhesion to the substrate, precise thickness and refractive index, and abrasion resistance. In this paper, abrasion‐resistant AR coatings were fabricated on polycarbonate substrates using the layer‐by‐layer spraying deposition of poly(allylamine hydrochloride) (PAH) and silica nanoparticles. The adhesion between the substrates and coatings was enhanced by treating the polycarbonate surfaces with aminopropyltrimethoxylsilane (APTS). The porous low‐refractive‐index PAH/silica‐nanoparticles multilayers were constructed by the layer‐by‐layer spraying of PAH and silica‐nanoparticles aqueous solutions onto the functionalized substrates. The subsequent treatment of the porous coatings with tetrahydroxylsilane leads to stable abrasion‐resistant AR coatings. The resultant AR coatings can reduce the reflection from 5 to 0.3%. The reported technique provides a cost‐effective method for large‐scale production of AR coatings on plastic substrates.     

World's first large size 77‐inch transparent flexible OLED display

Large flexible organic light‐emitting diode (OLED) display provides various electronic applications such as curved, bendable, rollable, and commercial display, because of its thinness, light weight, and design freedom. In this work, the process flow and key technologies to fabricate the world's first large size 77‐inch transparent flexible OLED display are introduced. “White OLED on TFT + color filter” method is used to fabricate the aforementioned display. On both thin‐film transistor and color filter substrates, transparent polyimide (PI) was used as plastic substrate with multi‐barrier. In case of a transparent flexible display, the multi‐barrier is required for the additional consideration to overcome the decrease of transmittance due to the difference in refractive index of the conventional multi‐barrier. We developed the special multi‐barrier to increase transparency with superior water vapor transition rate characteristic. The optimized amorphous indium gallium zinc oxide thin‐film transistors were employed on the multi‐barrier, and it shows the highly uniform electrical performance and reliability on plastic substrate. Also, the typical panel failure mechanism during laser lift‐off process caused by a particle in PI is studied, and a sacrificial layer was suggested between PI and a carrier glass to reduce the panel failure. Finally, we successfully realized the world's first 77‐inch transparent flexible OLED display with ultra‐high‐definition resolution, which can be rolled up to a radius of 80 mm with a transmittance of 40%.