1. Trillion Science 04/29/06RC Liang for TsingHua Univ. Toward Flexible and Roll-able Displays/Electronic Paper and Their R2R Manufacturing Processes R.C. Liang Trillion Science Mountain View, CA Rc.liang@trillionscience.com

2. Trillion Science 04/29/06RC Liang for TsingHua Univ. From CRT to Flexible Displays & Format Flexible ePaper ~100 years ago ~30 years ago ? ? ~1000 years ago

3. Trillion Science 04/29/06RC Liang for TsingHua Univ. Worldwide FPD Market

4. Trillion Science 04/29/06RC Liang for TsingHua Univ. Cost Structure of a 40” LCD TV The material cost accounts for 75% of the total manufacturing cost. ---Information Display, 22(2), p 12 (2006)---

5. Trillion Science 04/29/06RC Liang for TsingHua Univ. Flexible Display Market to Grow 83.5%/yr

6. Trillion Science 04/29/06RC Liang for TsingHua Univ. Hitachi ePaper 07/2005 400x440 Recent Developments Fujitsu 07/2005

7. Trillion Science 04/29/06RC Liang for TsingHua Univ. Recent Developments Magink & Mitsubishi Electric 06/2005 E-ink/Toppan 06/2005 Pull-out, roll-up display 08/2005; e-ink/Philips

8. Trillion Science 04/29/06RC Liang for TsingHua Univ. Conformal, Wearable, and Rollable Displays demonstrated recently

9. Trillion Science 04/29/06RC Liang for TsingHua Univ. Definition of Electronic Paper A display with the basic characteristics of printed media:  Compatibility with flexible substrates  No power required to maintain an image (bistability)  Wide viewing angle  Insensitive to ambient lighting and various humidity/temperature conditions. And preferably, -Low manufacturing cost -Low Operating cost -Format Flexibility -Easy Converting

10. Trillion Science 04/29/06RC Liang for TsingHua Univ. Paper vs. Displays Dot density required in printed media to match the resolution of a 200 ppi display with 24-bit color (IBM)  400 dpi typical 100 ppi of current electronic displays.  inexpensive 2400 dpi printers are now available for home and office uses. As of today, printed Media is still of much higher resolution and lower cost

11. Trillion Science 04/29/06RC Liang for TsingHua Univ. Technical Challenges for Rollable Displays & Roll-to-Roll Manufacturing General issues: Barrier properties, surface roughness and temperature resistance of substrate Mismatch of thermal expansion coefficients Flexure resistance of the electrodes Flexible Battery For LCDs: Cell gap control during bending/rolling Viewing angle Thickness & Light Management

12. Trillion Science 04/29/06RC Liang for TsingHua Univ. Flexible Display Technologies Flexible display technologies recently demonstrated may be categorized into three major groups: Those based on liquid crystal technologies such as polymer dispersed liquid crystal ( PDLC ), polymer encased LC, STN, cholesteric LC, ferroelectric LC, bi-stable TN, Microcup LC. Those based on light emitting diode technologies, OLED/PLED/PHOLED, CCM, ECL, and their hybrids. Others such as electrophoretic, gyroelectric, electrochromic, electrodeposition, conducting particles, and liquid powder.

13. Trillion Science 04/29/06RC Liang for TsingHua Univ. Contrast During Bending/Rolling -Changes of cell gap during bending may be controlled to about 50 nm by using spacers in fixed positions that are aligned with the ITO lines. -Fixing cell gap by microcup structure is a potential solution for roll-to-roll manufacturing of flexible displays with or without polarizers.

14. Trillion Science 04/29/06RC Liang for TsingHua Univ. Light/Power/Thickness Management Light Guide 100% Lamp Output Lamp Diffuser Reflector TAC Stretched PVA TAC LCD-cell Stretched A plate ( Polarizer Compensation film-1 or WV film) Color Filter TFT 85% 25% 90% 1000-2000 um 50-100 um 120-250 um TAC 50-100 um Stretched PVA TAC Polarizer Stretched & coated C plate Compensation film-2 (or WV film) 45% 120-250 um DBEF (recycle polarized light) 130 um 50% BEF (collect light) 155 um x2 2000- 3000 um ~4% transmitted

15. Trillion Science 04/29/06RC Liang for TsingHua Univ. Optical Films Currently Used in LCDs About 440um (C) X-plate oe TAC film 80um DBEF layers Diffuser Sheets PEN n= 1.64 n o ~ 1.64 ne~ 1.88 Stretched PEN (A) 3M DBEF Film Isotropic adhesive polarizer (C) X-Plate (D) Fuji Photo WV film WV Film LC Cell WV Film (E) Nippon Oil NH Film Film axis LCP <1um  n=0.236 polarizer ( B) A & C plates (for MVA Mode) polarizer C-plate, (n x =n y >n z) C-plate A-plate, (n x >n y =n z ) VA cell ηXηX ηYηY ηZηZ

16. Trillion Science 04/29/06RC Liang for TsingHua Univ. 3M DBEF Stacks DBEF layers Diffuser Sheets About 440um oe n o ~ 1.64 ne~ 1.88 PEN n= 1.64 Stretched PEN

17. Trillion Science 04/29/06RC Liang for TsingHua Univ. Brightness Enhancement Film by UV Curing Paliocolor LC242 2. UV curing 1. Stretching o oe Reflector/diffuser depolarize light Polaroid, 3M, Brown Univ. (B) Stretched LC dispersion Nitto, Philips, Reveo, BASF, OCLI, ROLIC, 3M, Charmica (A) Cholesteric LC films Polarizer ¼ Wave plate CLC stacks Backlight Unit Unpolarized light Circular polarized light Linearly Polarized light

18. Trillion Science 04/29/06RC Liang for TsingHua Univ. LC Coating LC film on carrier; Transfer Lamination or overcoating, if needed. DryingUV Curing Converting (5A) (5B) Brightness Enhancement Film by UV curing of CLC Acrylates (BASF)

19. Trillion Science 04/29/06RC Liang for TsingHua Univ. Polarizers by Coating TAC Stretched PVA/iodide TAC Polarizer Optiva Areas for future improvements: - Orientation for higher efficiency - Improve environmental stability (w/o protective films) - In-cell coating (not to scale)

20. Trillion Science 04/29/06RC Liang for TsingHua Univ. Cholesteric LC (Kent Display/Kodak) Homeotropic (transparent) Planar (Bragg Reflecting) Focal Conic Weakly Scattering Kent Display 1. UV induced phase separation of CLC/monomer mixture. Or 2. Pre-encapsulated CLC in binder.

21. Trillion Science 04/29/06RC Liang for TsingHua Univ. Monodispersed Microcup LCDs Conventional PDLC by UV-induced phase separation 10  m 2  m (l) x 2  m (w) x 1.5  m (p) 3  m (l) x 3  m (w) x 2.5  m (p) Microcup LCD

22. Trillion Science 04/29/06RC Liang for TsingHua Univ. Flexible Display Technologies Flexible display technologies recently demonstrated may be categorized into three major groups: Those based on liquid crystal technologies such as polymer dispersed liquid crystal (PDLC), polymer encased LC, STN, cholesteric LC, ferroelectric LC, bi-stable TN, Microcup LC. Those based on light emitting diode technologies, OLED/PLED/PHOLED, CCM, ECL, and their hybrids. Others such as electrophoretic, gyroelectric, electrochromic, electrodeposition, conducting particles, and liquid powder.

23. Trillion Science 04/29/06RC Liang for TsingHua Univ. PHOLED (Universal Display)

24. Trillion Science 04/29/06RC Liang for TsingHua Univ. Flexible OLED/PLED Printed PLED (DNP) Pioneer

25. Trillion Science 04/29/06RC Liang for TsingHua Univ. Barrier Properties

26. Trillion Science 04/29/06RC Liang for TsingHua Univ. - Pioneer: SiON passivation layer - Vitex System Multilayer AlOx/Acrylic system

27. Trillion Science 04/29/06RC Liang for TsingHua Univ. Flexible Display Technologies Flexible display technologies recently demonstrated may be categorized into three major groups: Those based on liquid crystal technologies such as polymer dispersed liquid crystal (PDLC), polymer encased LC, STN, cholesteric LC, ferroelectric LC, bi-stable TN, Microcup LC. Those based on light emitting diode technologies, OLED/PLED/PHOLED, CCM, ECL, and their hybrids. Others such as electrophoretic, gyroelectric, electrochromic, electrodeposition, conducting particles, and liquid powder. Others such as electrophoretic, gyroelectric, electrochromic, electrodeposition, conducting particles, and liquid powder.

28. Trillion Science 04/29/06RC Liang for TsingHua Univ. Conducting Particles (e.g. Citala) Radiation curing of particle dispersion in polymer matrix

29. Trillion Science 04/29/06RC Liang for TsingHua Univ. Rotating Balls (Gyricon Media) ElectroChromic Displays (N’Tera Ltd., Ireland and Uppsala Univ, Sweden)

30. Trillion Science 04/29/06RC Liang for TsingHua Univ. Microcapsule EPDs (e-Ink) Pull-out, roll-up display 08/2005

31. Trillion Science 04/29/06RC Liang for TsingHua Univ. Embossin g Roller Adhesive Transparent Conductor Cutter Finished EPD Film 1. Coating 2. Microembossing 3. Filling & Sealing 4. Lamination & Cutting EPD Fluid Transparent Conductor Microcup EPDs (SiPix Imaging) UV

32. Trillion Science 04/29/06RC Liang for TsingHua Univ. Continuous Filling & Sealing Process Phase separated Sealing material Phase separation Pre- dispersed sealing material hardening Controlling factors: Density Incompatibility Surface tension Viscosity Controlling factors: Density Incompatibility Surface tension Viscosity Seamless sealing may be accomplished in seconds. Phase separation and hardening Sealant material Two-phase Inter-mixing Overcoat sealing layer

33. Trillion Science 04/29/06RC Liang for TsingHua Univ. EPD Roll Microcup ® PMEPDs Lower Pattern Conductor Film Microcups w EPD fluid Adhesive/Sealing Layer Upper Conductor Film FPC and Driver IC Connectors Microcup ® AMEPDs a-Si TFT ITO/PET Microcup TiO2 particles Sealing/adhesive layer Viewing Side < +10 V Lamination To TFT EP panel Release liner Remove Release

34. Trillion Science 04/29/06RC Liang for TsingHua Univ. Rollable Microcup® EPDs Integrated by Polymer Vision, Philip

35. Trillion Science 04/29/06RC Liang for TsingHua Univ. Roll-able Microcup EPDs (SiPix)

36. Trillion Science 04/29/06RC Liang for TsingHua Univ. Conclusions Technical challenges exist in barrier, substrate, cell gap control, flexure resistance of electrodes, viewing angle, light and thickness management management, and manufacturing processes. Roll-to-roll manufacturing of EPD and other display technologies that are relatively insensitive to environment and cell gap are easier to realize. Plenty of rooms for new comers to play a key role in the technology breakthrough.

37. Trillion Science 04/29/06RC Liang for TsingHua Univ. Acknowledgement Special thanks to BASF Electronic Materials BU Delta Electronics & Delta Opto CMO About Trillion Science  A Mountain View, CA startup (2005-present) of 19 R&D staffs to develop next generation materials for displays, semiconductors, solar cells and fuel cells.  R.C. Liang, now CEO of Trillion, was the cofounder and inventor of the SiPix Microcup Technologies (1999-2004) and the executive advisor of the BASF Electronic Materials BU (2005) and Delta Electronics (2005-present).

38. Trillion Science 04/29/06RC Liang for TsingHua Univ. ECD Roll-to-Roll Flexible Solar Cell Akzo Nobel Roll-to-Roll Flexible Solar Cell Temporary Al foil Plastic film Others: Fujitsu, Sharp, Sanyo…etc

39. Trillion Science 04/29/06RC Liang for TsingHua Univ. Seamlessly Sealed Microcups ® Conductor film (ITO/PET) Conductor film Sealing/Adhesive Microcup Partition Cell gap: 15~30  m.

40. Trillion Science 04/29/06RC Liang for TsingHua Univ. CCM by Univ. of Cinn.

41. Trillion Science 04/29/06RC Liang for TsingHua Univ. Electrowetting (by Philips, Cornell Univ, RPI)

42. Trillion Science 04/29/06RC Liang for TsingHua Univ. Iridigm Digital Paper (A MEMS Based Display)

43. Trillion Science 04/29/06RC Liang for TsingHua Univ. Electrodeposition Displays (Sony) BridgeStone Liquid Powder