Flexible microelectronics becoming a reality with Suftla transfer technology

Abstract— Suftla is a technology that is used to transfer polycrystalline silicon (polysilicon) thin‐film‐transistor (TFT) circuits from an original glass substrate to a plastic sheet. The electronic devices in the next generation will be thin, lightweight, and will handle huge amounts of data, yet consume less energy. Suftla technology, together with high‐performance polysilicon TFTs, meets all these requirements because we have developed a variety of smart flexible electronic devices, such as thin paperback‐sized displays and microprocessors. Suftla will usher in a new era of life‐enhancing flexible microelectronics.     

Flexible AMOLEDs with low‐temperature‐processed TFT backplane technologies

Developments of backplane technologies, which are one of the challenging topics, toward the realization of flexible active matrix organic light‐emitting diodes (AMOLEDs) are discussed in this paper. Plastic substrates including polyimide are considered as a good candidate for substrates of flexible AMOLEDs. The fabrication process flows based on plastic substrates are explained. Limited by the temperature that plastic substrates can sustain, TFT technologies with maximum processing temperature below 400 °C must be developed. Considering the stringent requirements of AMOLEDs, both oxide thin‐film transistors (TFTs) and ultra‐low‐temperature poly‐silicon TFTs (U‐LTPS TFTs) are investigated. First, oxide TFTs with representative indium gallium zinc oxide channel layer are fabricated on polyimide substrates. The threshold voltage shifts under bias stress and under bending test are small. Thus, a 4.0‐in. flexible AMOLED is demonstrated with indium gallium zinc oxide TFTs, showing good panel performance and flexibility. Further, the oxide TFTs based on indium tin zinc oxide channel layer with high mobility and good stability are discussed. The mobility can be higher than 20 cm²/Vs, and threshold voltage shifts under both voltage stress and current stress are almost negligible, proving the potential of oxide TFT technology. On the other hand, the U‐LTPS TFTs are also developed. It is confirmed that dehydrogenation and dopant activation can be effectively performed at a temperature within 400 °C. The performance of U‐LTPS TFTs on polyimide is compatible to those of TFTs on glass. Also, the performance of devices on polyimide can be kept intact after devices de‐bonded from glass carrier. Finally, a 4.3‐in. flexible AMOLED is also demonstrated with U‐LTPS TFTs.     

Instability of light illumination stress on amorphous In–Ga–Zn–O thin‐film transistors

Amorphous In–Ga–Zn–O thin‐film transistors (TFTs) have attracted increasing attention due to their electrical performance and their potential for use in transparent and flexible devices. Because TFTs are exposed to illumination through red, green, and blue color filters, wavelength‐varied light illumination tests are required to ensure stable TFT characteristics. In this paper, the effects of different light wavelengths under both positive and negative V_GS stresses on amorphous In–Ga–Zn–O TFTs are investigated. The TFT instability that is dependent on optical and electrical stresses can be explained by the charge trapping mechanism and interface modification.     

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.     

Amorphous‐silicon thin‐film transistors made at 280°C on clear‐plastic substrates by interfacial stress engineering

Abstract— A process temperature of ～300°C produces amorphous‐silicon (a‐Si) thin‐film transistors (TFTs) with the best performance and long‐term stability. Clear organic polymers (plastics) are the most versatile substrate materials for flexible displays. However, clear plastics with a glass‐transition temperature (T_g) in excess of 300°C can have coefficients of thermal expansion (CTE) much larger than that of the silicon nitride (SiN^x) and a‐Si in TFTs deposited by plasma‐enhanced chemical vapor deposition (PECVD). The difference in the CTE that may lead to cracking of the device films can limit the process temperature to well below that of the T_g of the plastic. A model of the mechanical interaction of the TFT stack and the plastic substrate, which provides design guidelines for avoid cracking during TFT fabrication, is presented. The fracture point is determined by a critical interfacial stress. The model was used to successfully fabricate a‐Si TFTs on novel clear‐plastic substrates with a maximum process temperature of up to 280°C. The TFTs made at high temperatures have higher mobility, lower leakage current, and higher stability than TFTs made on conventional low‐T_g clear‐plastic substrates.     

Flexible amorphous‐silicon non‐volatile memory

Abstract— The development of a flexible, rewritable, non‐volatile memory (NVM) that is implemented on a standard, low‐temperature a‐Si:H process without additional mask steps is reported. This NVM is a part of a flexible‐display system. Each NVM cell is composed of differentially configured thin‐film‐transistors (TFTs). The cell reads out one of two stable states depending on the relative threshold voltages of the differentially configured TFTs. Information is stored in each cell by increasing the threshold voltage of one differential TFT or the other, utilizing the well‐known electrical‐stress degradation intrinsic to a‐Si:H TFTs. The stored information is retained indefinitely with no applied power. A test array of individually addressable NVM cells has been successfully fabricated and tested on flexible stainless‐steel substrates. Read and write operation, as well as preliminary reliability measurements, are described. The design is readily scalable to large memory arrays.     

Novel mobile TFT‐LCDs based on SLS technology

Abstract— Single‐crystal‐like silicon (SLS) technology is the most cost‐effective laser‐crystallization process ever invented. The throughput of the SLS process is about two times higher than that of the conventional excimer‐laser annealing (ELA) method. In addition, the performance of the TFTs fabricated by the SLS process is among the best utilized in mass production. Various TFT‐LCDs employing SLS technology, which included a 1.02‐in. full SOG LCD using an icon display for the sub‐display of cellular phones, a 1.9‐in. qVGA TFT‐LCD with a low‐power analog interface employing a low‐voltage driving scheme, and a 3.0‐in. VGA TFT‐LCD compatible with the 480i data format without additional signal processing were developed. Because the SLS process enables us to achieve highly uniform and reliable transistors, it can be effectively utilized in the mass production of mobile TFT‐LCDs with low power consumption and enhanced image quality.     

Impact of bending on flexible metal oxide TFTs and oscillator circuits

Thin‐film circuits on plastic capable of high‐frequency signal generation have important applications in large‐area, flexible hybrid systems, enabling efficient wireless transmission of power and information. We explore oscillator circuits using zinc‐oxide thin‐film transistors (ZnO TFTs) deposited by the conformal, layer‐by‐layer growth technique of plasma‐enhanced atomic layer deposition. TFTs on three substrates—glass, 50‐µm‐thick freestanding polyimide, and 3.5‐µm‐thick spin‐cast polyimide—are evaluated to identify the best candidate for high‐frequency flexible oscillators. We find that TFTs on ultrathin plastic can endure bending to smaller radii than TFTs on commercial 50‐µm‐thick freestanding polyimide, and their superior dimensional stability furthermore allows for smaller gate resistances and device capacitances. Oscillators on ultrathin plastic with minimized parasitics achieve oscillation frequencies as high as 17 MHz, well above the cutoff frequency f_T. Lastly, we observe a bending radius dependence of oscillation frequency for flexible TFT oscillators and examine how mitigating device parasitics benefits the oscillator frequency versus power consumption tradeoff.     

Highly reliable a‐IGZO TFTs on a plastic substrate for flexible AMOLED displays

We have successfully reduced threshold voltage shifts of amorphous In–Ga–Zn–O thin‐film transistors (a‐IGZO TFTs) on transparent polyimide films against bias‐temperature stress below 100 mV, which is equivalent to those on glass substrates. This high reliability was achieved by dense IGZO thin films and annealing temperature below 300 °C. We have reduced bulk defects of IGZO thin films and interface defects between gate insulator and IGZO thin film by optimizing deposition conditions of IGZO thin films and annealing conditions. Furthermore, a 3.0‐in. flexible active‐matrix organic light‐emitting diode was demonstrated with the highly reliable a‐IGZO TFT backplane on polyimide film. The polyimide film coating process is compatible with mass‐production lines. We believe that flexible organic light‐emitting diode displays can be mass produced using a‐IGZO TFT backplane on polyimide films.     

Effects of post‐annealing on a‐Si:H TFT characteristics fabricated on stainless‐steel substrate

Abstract— A 14.1‐in.‐diagonal backplane employing hydrogenated amorphous‐silicon thin‐film transistors (a‐Si:H TFTs) was fabricated on a flexible stainless‐steel substrate. The TFTs exhibited a field‐effect mobility of 0.54 cm²/V‐sec, a threshold voltage of 1.0 V, and an off‐current of 10^?13 A. Most of the electrical characteristics were comparable to those of the TFTs fabricated on glass substrates. To increase the stability of a‐Si:H TFTs fabricated on stainless‐steel substrate, the specimens were thermally annealed at 230°C. The field‐effect mobility was reduced to 71% of the initial value because of the strain of the released hydrogen atoms and residual compressive stress in a‐Si:H TFT under thermal annealing at 230°C.     

Active‐matrix organic light‐emitting diode displays with indium gallium zinc oxide thin‐film transistors and normal,inverted, and transparent organic light‐emitting diodes

Abstract— Active‐matrix organic light‐emitting diode (AMOLED) displays have gained wide attention and are expected to dominate the flat‐panel‐display industry in the near future. However, organic light‐emitting devices have stringent demands on the driving transistors due to their current‐driving characteristics. In recent years, the oxide‐semiconductor‐based thin‐film transistors (oxide TFTs) have also been widely investigated due to their various benefits. In this paper, the development and performance of oxide TFTs will be discussed. Specifically, effects of back‐channel interface conditions on these devices will be investigated. The performance and bias stress stability of the oxide TFTs were improved by inserting a SiO^x protection layer and an N²O plasma treatment on the back‐channel interface. On the other hand, considering the n‐type nature of oxide TFTs, 2.4‐in. AMOLED displays with oxide TFTs and both normal and inverted OLEDs were developed and their reliability was studied. Results of the checkerboard stimuli tests show that the inverted OLEDs indeed have some advantages due to their suitable driving schemes. In addition, a novel 2.4‐in. transparent AMOLED display with a high transparency of 45% and high resolution of 166 ppi was also demonstrated using all the transparent or semi‐transparent materials, based on oxide‐TFT technologies.     

Negative bias illumination stress assessment of indium gallium zinc oxide thin‐film transistors

Electrical performance stability of indium gallium zinc oxide (IGZO) thin‐film transistors (TFTs) is evaluated under negative bias illumination stress (NBIS). A bottom‐gate IGZO TFT whose top surface is passivated with zinc tin silicon oxide (ZTSO) exhibits a dramatic improvement in NBIS stability compared with that of an unpassivated, bottom‐gate IGZO TFT. Oxygen chemisorption/desorption at the channel layer top surface is proposed to explain why an unpassivated TFT exhibits significantly more NBIS than a passivated TFT.     

Novel top‐gate zinc oxide thin‐film transistors (ZnO TFTs) for AMLCDs

Abstract— High‐performance top‐gate thin‐film transistors (TFTs) with a transparent zinc oxide (ZnO) channel have been developed. ZnO thin films used as active channels were deposited by rf magnetron sputtering. The electrical properties and thermal stability of the ZnO films are controlled by the deposition conditions. A gate insulator made of silicon nitride (SiN_x) was deposited on the ZnO films by conventional P‐CVD. A novel ZnO‐TFT process based on photolithography is proposed for AMLCDs. AMLCDs having an aperture ratio and pixel density comparable to those of a‐Si:H TFT‐LCDs are driven by ZnO TFTs using the same driving scheme of conventional AMLCDs.     

Active‐matrix organic light‐emitting displays employing two thin‐film‐transistor a‐Si:H pixels on flexible stainless‐steel foil

Abstract— An active‐matrix organic light‐emitting diode (AMOLED) display driven by hydrogenated amorphous‐silicon thin‐film transistors (a‐Si:H TFTs) on flexible, stainless‐steel foil was demonstrated. The 2‐TFT voltage‐programmed pixel circuits were fabricated using a standard a‐Si:H process at maximum temperature of 280°C in a bottom‐gate staggered source‐drain geometry. The 70‐ppi monochrome display consists of (48 × 4) × 48 subpixels of 92 ×369 μm each, with an aperture ratio of 48%. The a‐Si:H TFT pixel circuits drive top‐emitting green electrophosphorescent OLEDs to a peak luminance of 2000 cd/m².     

Temporary bond—debond technology for high‐performance transistors on flexible substrates

Abstract— A processing technology based upon a temporary bond—debond approach has been developed that enables direct fabrication of high‐performance electronic devices on flexible substrates. This technique facilitates processing of flexible plastic and metal‐foil substrates through automated standard semiconductor and flat‐panel tool sets without tool modification. The key to processing with these tool sets is rigidifying the flexible substrates through temporary bonding to carriers that can be handled in a similar manner as silicon wafers or glass substrates in conventional electronics manufacturing. To demonstrate the power of this processing technology, amorphous‐silicon thin‐film‐transistor (a‐Si:H TFT) backplanes designed for electrophoretic displays (EPDs) were fabricated using a low‐temperature process (180°C) on bonded‐plastic and metal‐foil substrates. The electrical characteristics of the TFTs fabricated on flexible substrates are found to be consistent with those processed with identical conditions on rigid silicon wafers. These TFTs on plastic exhibit a field‐effect mobility of 0.77 cm²/V‐sec, on/off current ratio >10⁹ at Vds = 10 V, sub‐threshold swing of 365 mV/dec, threshold voltage of 0.49 V, and leakage current lower than 2 pA/μm gate width. After full TFT‐array fabrication on the bonded substrate and subsequent debonding, the flexible substrate retains its original flexibility; this enables bending of the EPD display without loss in performance.     

A new a‐Si:H TFT pixel circuit employing data‐reflected negative‐bias annealing for a stable and uniform AMOLED

Abstract— A new a‐Si:H pixel circuit to reduce the VTH degradation of driving a‐Si:H thin‐film transistors (TFTs) by data‐reflected negative‐bias annealing (DRNBA) is presented. The new pixel circuit compensates VTH variation induced by non‐uniform degradation of each a‐Si:H pixel due to various electrical stress. The proposed pixel circuit was verified by SPICE simulations. Although the VTH of the driving a‐Si:H TFT varies from 2.5 to 3.0 and 3.5 V, the organic light‐emitting diode (OLED) current changes by only 1.5 and 2.8% in the emission period, respectively. During the negative‐bias annealing period, the negative VGS is applied to the driving TFT by using its own data signal. It is expected that the VTH shift of the driving TFT can be effectively reduced and the VTH shift can be compensated for in our new pixel circuit, which can contribute to a stable and uniform image from an a‐Si:H TFT active‐matrix OLED.     

Active‐matrix field‐emission display based on a CNT emitter and a‐Si TFTs

Abstract— An active‐matrix field‐emission display (AMFED), based on carbon‐nanotube (CNT) emitters and amorphous‐silicon thin‐film transistors (a‐Si TFTs), was developed. The AMFED pixels consisted of a high‐voltage a‐Si TFT and mesh‐gated CNT emitters. The AMFED panel demonstrated high performance for a driving voltage less than 15 V. The low‐cost large‐area AMFED approach using a metal‐mesh technology is proposed.     

Threshold‐voltage‐compensation methods for AMOLED pixel and analog buffer circuits

Abstract— New pixel‐circuit designs for active‐matrix organic light‐emitting diodes (AMOLEDs) and a new analog buffer circuit for the integrated data‐driver circuit of active‐matrix liquid‐crystal displays (AMLCDs) and AMOLEDs, based on low‐temperature polycrystalline‐silicon thin‐film transistors (LTPS‐TFTs), were proposed and verified by SPICE simulation and measured results. Threshold‐voltage‐compensation pixel circuits consisting of LTPS‐TFTs, an additional control signal line, and a storage capacitor were used to enhance display‐image uniformity. A diode‐connected concept is used to calibrate the threshold‐voltage variation of the driving TFT in an AMOLED pixel circuit. An active load is added and a calibration operation is applied to study the influences on the analog buffer circuit. The proposed circuits are shown to be capable of minimizing the variation from the device characteristics through the simulation and measured results.     

Solution‐processed and low‐temperature metal oxide n‐channel thin‐film transistors and low‐voltage complementary circuitry on large‐area flexible polyimide foil

High‐performance solution‐based n‐type metal oxide thin‐film transistors (TFTs), fabricated directly on polyimide foil at a post‐annealing temperature of only 250 °C, are realized and reported. Saturation mobilities exceeding 2 cm²/(Vs) and on‐to‐off current ratios up to 10⁸ are achieved. The usage of these oxide n‐type TFTs as the pixel drive and select transistors in future flexible active‐matrix organic light‐emitting diode (AMOLED) displays is proposed. With these oxide n‐type TFTs, fast and low‐voltage n‐type only flexible circuitry is demonstrated. Furthermore, a complete 8‐bit radio‐frequency identification transponder chip on foil has been fabricated and measured, to prove that these oxide n‐type TFTs have reached already a high level of yield and reliability. The integration of the same solution‐based oxide n‐type TFTs with organic p‐type TFTs into hybrid complementary circuitry on polyimide foil is demonstrated. A comparison between both the n‐type only and complementary elementary circuitry shows the high potential of this hybrid complementary technology for future line‐drive circuitry embedded at the borders of flexible AMOLED displays.     

Solution‐processed oxide semiconductors for low‐cost and high‐performance thin‐film transistors and fabrication of organic light‐emitting‐diode displays

Abstract— High‐performance solution‐processed oxide‐semiconductor (OS) thin‐film transistors (TFTs) and their application to a TFT backplane for active‐matrix organic light‐emitting‐diode (AMOLED) displays are reported. For this work, bottom‐gated TFTs having spin‐coated amorphous In‐Zn‐O (IZO) active layers formed at 450°C have been fabricated. A mobility (μ) as high as 5.0 cm²/V‐sec, ?0.5 V of threshold voltage (VT), 0.7 V/dec of subthreshold swing (SS), and 6.9 × 10⁸ of on‐off current ratio were obtained by using an etch‐stopper (ES) structure TFT. TFTs exhibited uniform characteristics within 150 × 150‐mm² substrates. Based on these results, a 2.2‐in. AMOLED display driven by spin‐coated IZO TFTs have also been fabricated. In order to investigate operation instability, a negative‐bias‐temperature‐stress (NBTS) test was carried out at 60°C in ambient air. The IZO‐TFT showed ?2.5 V of threshold‐voltage shift (ΔVT) after 10,800 sec of stress time, comparable with the level (ΔVT = ?1.96 V) of conventional vacuum‐deposited a‐Si TFTs. Also, other issues regarding solution‐processed OS technology, including the instability, lowering process temperature, and printable devices are discussed.