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Flexible Colour Active Matrix EP
   Display Using Low Distortion
              oTFT Backplanes

                        Paul Cain




                  7th June 2012
Speaker Introduction
    Flexible Colour Active Matrix EP Display Using Low
                Distortion oTFT Backplanes


Paul Cain, PhD CEng
Senior Manager, Technology
Plastic Logic, Cambridge UK.


•   Over 10 years at Plastic Logic
•   Focus on novel processes, device architectures, new technology integration
•   Technology Transfer to Dresden Production Facility
•   Over 20 patents / applications
•   PhD Physics (Cavendish Laboratory, Cambridge University)

                              SID Displayweek 2012             June 7th 2012   2
Plastic Electronics Technology
Uses plastic instead of traditional silicon semiconductors
 and glass
Enables a revolutionary design and form-factor

  Shatterproof, Thin, Large and Light Display
Company History
                                       Display Development




10+ transistors         100+ transistors      1.2 M transistors       Colour EPD             2.8 M transistors




                  Research, Process Development & Manufacturing




                                       2000: Cambridge Technology      2008: Dresden Display Factory
     Cambridge University               Center translating research   First plastic electronics factory in
     Research in organic electronics           into products                        the world



                                           SID Displayweek 2012                           June 7th 2012      4
The Manufacturing Challenge
It is one thing to show a single display at a tradeshow…




...quite another to develop a high yield manufacturing process

                       SID Displayweek 2012     June 7th 2012   5
R&D and Production Set-Up

                          Technology

                             Transfer
   Cambridge R&D
  Prototype Line (14”)


             Cambridge R&D Prototype Line
                                          Proof of concepts
                                          Highly configurable process
                                          New designs in < 1 month
                                          1” Chips to A4 displays
                                          R&D Engineers




                         SID Displayweek 2012             June 7th 2012   6
R&D and Production Set-Up

                Technology

                   Transfer

                                      Dresden Factory (Gen 3.5)


          Dresden Gen. 3.5 Factory
                              Backplane Manufacturing
                              Qualified volume process
                              Production equipment
                              Fully Automated Handling
                              Process, Equipment, Integration
                               Engineers
                              Thousands of displays/week


               SID Displayweek 2012                 June 7th 2012   7
Electrophoretic Plastic Display




                  SID Displayweek 2012   June 7th 2012   8
Electrophoretic Display Media




                SID Displayweek 2012   June 7th 2012   9
Distortion
                                            Flexible substrate


      GLASS                                                      RIGID CARRIER

 FPD industry processes designed assuming glass substrates
 Processing on flexible plastic:
     Dimensions affected by temperature, humidity
     Irreversible and reversible components.

 Multiple methods used to reduce distortion
     Low temperature processing
     Reduced thickness flexible substrate
     High Tg substrate material (eg PI)
 Trade-offs with each approach

 Plastic Logic approach re-sets distortion by design, without losing pixel
  performance:
     Common substrates to be used (eg PET)
     Mounted or un-mounted plastic substrates (eg Roll to roll)

                                 SID Displayweek 2012               June 7th 2012   10
Low Distortion Backplane - Design
                                                                                    Pixel
 Conventional glass                                                                Electrode
  backplanes require regular
  grid for all layers
                                                                                      Interlayer
  (source, drain, gate, via, etc                             Via                      Dielectric
  )

 This allows overlay of pre-
  patterned layers (eg Colour
  Filter)

 Distortion in flexible
  substrates makes this
  difficult

 Plastic Logic Process resets
  distortion at the pixel
  electrode layer, with no loss                                    Plastic Backplane: Top Pixels
                                Glass Backplane: All stack
  in pixel performance.           layers on a regular grid          maintained on a regular grid


                                     SID Displayweek 2012                  June 7th 2012        11
Low Distortion Backplane - Measured




 Backplane distortion measured
 OGP Vantage coordinate                         Measurement Area 217.6mm x
  measurement system used                         163.2mm
 Distortion controllable to < 5um in            150 PPI Backplane
  production.                                    100 point sample
                                                 Maximum measured deviation
                                                    ∆X [-2.3, 1.8] µm
                                                    ∆Y [-3.1, 4.1] µm
                                SID Displayweek 2012            June 7th 2012   12
Colour EP Display Architecture

                   Encapsulation sheet                          Colour Filter Array
                     Plastic Substrate
                                                                E Ink Frontplane

             Plastic Logic Backplane Technology
                                                                Low Distortion Plastic
                 Plastic Substrate                              Logic Backplane



 Colour Filter patterned by multiple approaches (wet printing, sheet-to-sheet
  alignment).
 During CFA pattern formation, the backplane pixel electrodes are not
  visible (obscured by E Ink layer).

 Backplane:
    1280 x 960 pixels (monochrome) = 640 x 480 Colour
    150PPI (monochrome) = 75PPI Colour
    Active Area: 217.6mm x 163.2mm

                                         SID Displayweek 2012          June 7th 2012     13
Colour Filter Overlay
 RGBW colour filter patterned onto E Ink surface

 Overlay accuracy of 10µm achieved across the active area

 Four variants of different colour density investigated




      RGBW CFA pattern over E Ink            R pixels driven “white” to show alignment

                                SID Displayweek 2012                 June 7th 2012   14
Colour Display Performance - Gamut
                                       4 colour densities tested
                                        (A,B,C,D)

                                       Gamut (∆E3):

                                               Type A: 5000
                                               Type B: 4000
                                               Type C: 3400
                                               Type D: 3000

                                       Excellent colour
                                        uniformity, viewing angle




                               Acknowledgement: A. Bouchard, E Ink
              SID Displayweek 2012                  June 7th 2012    15
Colour Display Performance - White
                                                              Acknowledgement: A. Bouchard, E Ink
                            D




                                       C


                                                         B




                                                               Type A




 25% white state reflectivity achieved
 No compromise in optical performance over glass colour filters / backplanes.

                                  SID Displayweek 2012                  June 7th 2012     16
Colour Display Performance
                                                    Display size                  10.7”
                                            Backplane subpixel resolution       1280 x 960
                                                   Subpixel pitch           170um (150subPPI)
                                               Backplane Grey Levels                16
                                                       NTSC                       2-5%
                                                   Contrast Ratio                  12:1
                                                    Reflectance                  50-57 L*




 Good white state maintained whilst achieving useful colour gamut
 Excellent contrast maintained due to excellent black state.
 Colour uniformity good across 10.7” display area.



                                SID Displayweek 2012                                  June 7th 2012   17
Colour Display Performance
      Display size          10.7”
   Backplane subpixel     1280 x 960
       resolution
     Subpixel pitch          170um
                          (150subPPI)
 Backplane Grey Levels         16
        NTSC                  2-5%
    Contrast Ratio            12:1
      Reflectance           50-57 L*

 Excellent readability maintained
     (High contrast)
 Colour gamut high enough to
  enable distinguishability
 Paper-like finish for the colour
  display (no glass layer above the
  display)



                                SID Displayweek 2012   June 7th 2012   18
Process enables higher resolutions….




                SID Displayweek 2012   June 7th 2012   19
Summary
 We have developed a new approach to manufacture low distortion
  flexible plastic displays:

     Compatible with lower cost substrate materials,
     Process qualified for production,
     Allows integration with a wider range pre-pixelated materials

 We have shown 75 PPI 10.7” colour displays using this qualified
  process

     Measured performance equivalent to glass EPD colour
     Visual performance enhanced due to absence of glass colour
      filter.

 For demonstrations of our technology, including colour please visit
  the Plastic Logic YouTube Channel:
                  http://www.youtube.com/user/PlasticLogic
                             SID Displayweek 2012            June 7th 2012   20
http://www.plasticlogic.com




   SID Displayweek 2012       June 7th 2012   21

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Plastic Logic Flexible Colour Active Matrix EP Display Using Low Distortion oTFT Backplanes

  • 1. Flexible Colour Active Matrix EP Display Using Low Distortion oTFT Backplanes Paul Cain 7th June 2012
  • 2. Speaker Introduction Flexible Colour Active Matrix EP Display Using Low Distortion oTFT Backplanes Paul Cain, PhD CEng Senior Manager, Technology Plastic Logic, Cambridge UK. • Over 10 years at Plastic Logic • Focus on novel processes, device architectures, new technology integration • Technology Transfer to Dresden Production Facility • Over 20 patents / applications • PhD Physics (Cavendish Laboratory, Cambridge University) SID Displayweek 2012 June 7th 2012 2
  • 3. Plastic Electronics Technology Uses plastic instead of traditional silicon semiconductors and glass Enables a revolutionary design and form-factor Shatterproof, Thin, Large and Light Display
  • 4. Company History Display Development 10+ transistors 100+ transistors 1.2 M transistors Colour EPD 2.8 M transistors Research, Process Development & Manufacturing 2000: Cambridge Technology 2008: Dresden Display Factory Cambridge University Center translating research First plastic electronics factory in Research in organic electronics into products the world SID Displayweek 2012 June 7th 2012 4
  • 5. The Manufacturing Challenge It is one thing to show a single display at a tradeshow… ...quite another to develop a high yield manufacturing process SID Displayweek 2012 June 7th 2012 5
  • 6. R&D and Production Set-Up Technology Transfer Cambridge R&D Prototype Line (14”) Cambridge R&D Prototype Line  Proof of concepts  Highly configurable process  New designs in < 1 month  1” Chips to A4 displays  R&D Engineers SID Displayweek 2012 June 7th 2012 6
  • 7. R&D and Production Set-Up Technology Transfer Dresden Factory (Gen 3.5) Dresden Gen. 3.5 Factory  Backplane Manufacturing  Qualified volume process  Production equipment  Fully Automated Handling  Process, Equipment, Integration Engineers  Thousands of displays/week SID Displayweek 2012 June 7th 2012 7
  • 8. Electrophoretic Plastic Display SID Displayweek 2012 June 7th 2012 8
  • 9. Electrophoretic Display Media SID Displayweek 2012 June 7th 2012 9
  • 10. Distortion Flexible substrate GLASS RIGID CARRIER  FPD industry processes designed assuming glass substrates  Processing on flexible plastic:  Dimensions affected by temperature, humidity  Irreversible and reversible components.  Multiple methods used to reduce distortion  Low temperature processing  Reduced thickness flexible substrate  High Tg substrate material (eg PI)  Trade-offs with each approach  Plastic Logic approach re-sets distortion by design, without losing pixel performance:  Common substrates to be used (eg PET)  Mounted or un-mounted plastic substrates (eg Roll to roll) SID Displayweek 2012 June 7th 2012 10
  • 11. Low Distortion Backplane - Design Pixel  Conventional glass Electrode backplanes require regular grid for all layers Interlayer (source, drain, gate, via, etc Via Dielectric )  This allows overlay of pre- patterned layers (eg Colour Filter)  Distortion in flexible substrates makes this difficult  Plastic Logic Process resets distortion at the pixel electrode layer, with no loss Plastic Backplane: Top Pixels Glass Backplane: All stack in pixel performance. layers on a regular grid maintained on a regular grid SID Displayweek 2012 June 7th 2012 11
  • 12. Low Distortion Backplane - Measured  Backplane distortion measured  OGP Vantage coordinate  Measurement Area 217.6mm x measurement system used 163.2mm  Distortion controllable to < 5um in  150 PPI Backplane production.  100 point sample  Maximum measured deviation  ∆X [-2.3, 1.8] µm  ∆Y [-3.1, 4.1] µm SID Displayweek 2012 June 7th 2012 12
  • 13. Colour EP Display Architecture Encapsulation sheet Colour Filter Array Plastic Substrate E Ink Frontplane Plastic Logic Backplane Technology Low Distortion Plastic Plastic Substrate Logic Backplane  Colour Filter patterned by multiple approaches (wet printing, sheet-to-sheet alignment).  During CFA pattern formation, the backplane pixel electrodes are not visible (obscured by E Ink layer).  Backplane:  1280 x 960 pixels (monochrome) = 640 x 480 Colour  150PPI (monochrome) = 75PPI Colour  Active Area: 217.6mm x 163.2mm SID Displayweek 2012 June 7th 2012 13
  • 14. Colour Filter Overlay  RGBW colour filter patterned onto E Ink surface  Overlay accuracy of 10µm achieved across the active area  Four variants of different colour density investigated RGBW CFA pattern over E Ink R pixels driven “white” to show alignment SID Displayweek 2012 June 7th 2012 14
  • 15. Colour Display Performance - Gamut  4 colour densities tested (A,B,C,D)  Gamut (∆E3):  Type A: 5000  Type B: 4000  Type C: 3400  Type D: 3000  Excellent colour uniformity, viewing angle Acknowledgement: A. Bouchard, E Ink SID Displayweek 2012 June 7th 2012 15
  • 16. Colour Display Performance - White Acknowledgement: A. Bouchard, E Ink D C B Type A  25% white state reflectivity achieved  No compromise in optical performance over glass colour filters / backplanes. SID Displayweek 2012 June 7th 2012 16
  • 17. Colour Display Performance Display size 10.7” Backplane subpixel resolution 1280 x 960 Subpixel pitch 170um (150subPPI) Backplane Grey Levels 16 NTSC 2-5% Contrast Ratio 12:1 Reflectance 50-57 L*  Good white state maintained whilst achieving useful colour gamut  Excellent contrast maintained due to excellent black state.  Colour uniformity good across 10.7” display area. SID Displayweek 2012 June 7th 2012 17
  • 18. Colour Display Performance Display size 10.7” Backplane subpixel 1280 x 960 resolution Subpixel pitch 170um (150subPPI) Backplane Grey Levels 16 NTSC 2-5% Contrast Ratio 12:1 Reflectance 50-57 L*  Excellent readability maintained  (High contrast)  Colour gamut high enough to enable distinguishability  Paper-like finish for the colour display (no glass layer above the display) SID Displayweek 2012 June 7th 2012 18
  • 19. Process enables higher resolutions…. SID Displayweek 2012 June 7th 2012 19
  • 20. Summary  We have developed a new approach to manufacture low distortion flexible plastic displays:  Compatible with lower cost substrate materials,  Process qualified for production,  Allows integration with a wider range pre-pixelated materials  We have shown 75 PPI 10.7” colour displays using this qualified process  Measured performance equivalent to glass EPD colour  Visual performance enhanced due to absence of glass colour filter.  For demonstrations of our technology, including colour please visit the Plastic Logic YouTube Channel: http://www.youtube.com/user/PlasticLogic SID Displayweek 2012 June 7th 2012 20
  • 21. http://www.plasticlogic.com SID Displayweek 2012 June 7th 2012 21