Flexible LCDs fabricated with a slit coater: Not requiring an alignment film

A homogeneously aligned liquid crystal layer on a substrate film on which it is not necessary to form a liquid crystal alignment film can be assembled by a slit coater. Types of twisted nematic and in‐plane switching flexible liquid crystal displays were demonstrated. The production time can be considerably shortened because of the lack of need for an alignment film. The slit coater method is also applicable to the roll‐to‐roll process.     

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.     

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.     

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.     

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.     

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.     

Properties of azo‐dye alignment layer on plastic substrates

Abstract— The alignment properties of the azo‐dye photo‐alignment material SD‐1/SDA‐2 on plastic substrates are investigated. Important liquid‐crystal cell parameters, such as azimuthal and polar anchoring energy, pretilt angle, voltage holding ratio, and the corresponding electro‐optical properties are presented. Excellent alignment with high anchoring energy can be achieved with a polarized UV dose less than 1.0 J/cm². A reflective six‐digit flexible passive‐matrix‐driven TN‐LCD for smart‐card applications showing excellent electro‐optical properties is demonstrated.     

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.     

A4‐sized flexible ferroelectric liquid‐crystal displays with micro color filters

Abstract— We demonstrated an A4‐paper‐sized flexible ferroelectric liquid‐crystal (FLC) color displays fabricated by using a new plastic‐substrate‐based process which was developed for large‐sized devices. Finely patterned color filters and ITO electrodes were formed on a plastic substrate by a transfer method to avoid surface roughness and thermal distortion of the substrate, which induce disordering of the FLC molecular alignment. The thickness of an FLC/monomer solution sandwiched by two plastic‐film substrates was well controlled over a large area by using flexographic printing and lamination techniques. Molecular‐aligned polymer walls and fibers were formed in the FLC by a two‐step photopolymerization‐induced phase‐separation method using UV‐light irradiation. A fabricated A4‐sized flexible‐sheet display for color‐segment driving was able to exhibit color images even when it was bent.     

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.     

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.     

Progress in flexible and drapable reflective cholesteric displays

Abstract— Recent results from encapsulation work on the development of flexible and drapable cholesteric liquid‐crystal displays (LCDs) on substrates such as thin plastics, fabrics, and even paper will be presented. The approaches used to create flexible displays using single‐ and dual‐substrate methods based on printable emulsions and polymerization‐induced phase‐separation (PIPS) techniques will be discussed.     

Fabrication of a highly bendable LCD with an elastomer substrate by using a replica‐molding method

Abstract— A highly bendable liquid‐crystal display was fabricated by using a multi‐functional elastomer substrate of self‐aligning LC molecules without any surface treatment. One of the two substrates is a plastic substrate while the other is a multi‐functional elastomer substrate produced by a replica‐molding technique. The multi‐functional elastomer substrate has pixel‐encapsulating walls that serve as spacers and provide mechanical stability and reproducibility against bending deformations. The highly bendable LCD demonstrates great flexibility, durability, and excellent electro‐optic performances in a highly bent state.     

A polarizer‐free flexible display using dye‐doped liquid‐crystal gels

Abstract— A reflective‐type polarizer‐free flexible display using a dye‐doped liquid‐crystal (LC) gels is demonstrated. Compared to the conventional guest‐host LC mode, it has high contrast ratio and brightness due to the combining of both scattering and absorption. Such a gel‐like flexible display is bendable and trimable. In this paper, a three‐step switch using distinct dye‐doped LC gels is also demonstrated. The potential applications are e‐paper and decorative displays.     

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.     

Plasma‐beam alignment of passive liquid crystals (Invited Paper)

Abstract— A plasma‐beam process, developed for the alignment of liquid crystals (LC) in electro‐optic applications, has been successfully applied to align “non‐standard” LC, such as crystalline materials with LC phases at elevated temperatures and reactive mesogenes. In addition to the high alignment quality of the materials, there is no need for an intermediate layer between the substrate and the LC layer. Furthermore, the construction of our source simplifies the alignment procedure of large‐area rigid substrates and the roll‐to‐roll processing of flexible films. This method opens new horizons for optical retarders and polarizers, as well as anisotropic semiconducting films for organic electronics.     

Deformed nanostructure of photo‐induced biaxial cholesteric films and their application in VA‐mode LCDs

Abstract— Novel biaxial retardation films made from photo‐induced deformed cholesteric liquid‐crystal (LC) nanostructures using reactive mesogen mixtures (RMMs) for a viewing‐angle compensation of vertically aligned liquid‐crystal displays (VA‐LCDs) was developed. The deformed cholesteric LC nanostructure has been observed by X‐ray‐diffraction (XRD) measurement. The birefringence of the film was described well by our optical model based on a form birefringence theory. The VA‐LCDs with photo‐induced biaxial cholesteric films have excellent viewing‐angle properties.     

Seventeen‐inch laser backlight in‐plane switching liquid crystal display with 8K, 120‐Hz driving,and BT.2020 color gamut

We have developed a 17‐inch laser backlight in‐plane switching liquid crystal display satisfying the main BT.2020 specifications, which are 8K, 120‐Hz driving, and a BT.2020 wide color gamut. The color gamut of the developed in‐plane switching liquid crystal display covers 98% of the BT.2020 wide color gamut, thanks to a laser backlight and appropriate color filters. The liquid crystal response time of 5 ms, which is sufficient for 120‐Hz driving, is achieved by adapting a faster in‐plane switching liquid crystal display, namely, the short‐range lurch control in‐plane switching liquid crystal display.     

A new vertical‐alignment LC mode with high‐transmittance and fast‐response‐time features

Abstract— A novel pixel design for vertical‐alignment LCDs with superior transmittance has been developed. The new liquid‐crystal mode, refered to as the hole‐induced vertical‐alignment mode (Hi‐VA), uses a via hole of an organic layer on a TFT substrate to achieve multi‐domain alignment. Compared to the conventional design, the Hi‐VA mode has a transmittance of up to 135% with a contrast ratio of 2000:1. Moreover, the new structure is free from ITO patterning or protrusion on the color‐filter side, which makes the fabrication process simple and low cost.     

Development of a liquid crystal with fine‐pitch light‐source display (LFD) using an organic light‐emitting diode (OLED)

Abstract— A novel display system, refered to as an LFD (liquid crystal with fine‐pitch light‐source display) is proposed. In an LFD, an auxiliary light source patterned with a fine pitch is attached to a reflective liquid‐crystal display (LCD), and a light shield is formed on the observer's side of the light source. A vertical‐alignment LCD (VA‐LCD) is attached as the reflective LCD, and an organic light‐emitting diode (OLED) is attached as the fine‐pitch light source. An LFD can produce bright, high‐contrast images under any ambient light. A test sample was built and its display characteristics confirmed.