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It a time when cost of PCs and electronics goods is going down and profit margins are taking a hit, display manufacturing companies are realizing the importance of implementing innovative ideas. To help achieve this, UK Displays Network (UKDL), a UK-based network of display manufacturing companies has taken a lead and is closely working with manufacturers across the world and India to help them in display matters at all levels of industry, commerce and academia. The network helps engineers and scientists in research, display materials, production equipment and display device manufacturing. It encourages commercial and industrial collaborations between members; helping manufacturers reduce their production risk apart from reducing the time to market with an overall reduction in cost.

The activities include displays, lighting, and supporting technologies through manufacturing. This ranges from the point of initial scientific invention to the point of product disassembly, recycling and safe disposal of materials at the end of life. Chris Williams, network director, is a co-founder of UKDL. The Department of Trade and Industry, Government of UK under the Technology Program have funded it. It works closely with the Universities of Swansea and Dundee. UKDL also has close association with technical societies, institutions, government bodies and sources of finance.

Advantages
The display technologies- materials, processes, production equipments-are developed in the UK. They are of two main types: those that are designed for use within existing commercially available display technology production systems used at manufacturers in the Far East, and those that are completely new and require new ideas and new thinking to organize mass production.

According to Williams, "In looking to exploit the new technology area of flexible displays, the UK community is drawing heavily on the experience of those companies who have been involved in the printing industry for several decades. This collaboration is allowing high tech display companies fast-track their production process developments."

Inventions Galore
There are companies like ZBD who have invented a type of liquid crystal technology that can be mass-produced on existing STN LCD production lines, with just one small change to the production process. This helps in simple displays becoming bi-stable (when the information is written to the display, it then requires no power to maintain that display). This is considered to be an ideal solution for retail signs and labels.

Patterning Technologies and other companies are developing printing equipments that can be used to deposit materials used in different layers of STN and Active Matrix LCD, and Plasma displays. Other companies are developing new metalization materials (transparent and opaque) to replace the current materials used in mass production. For example, Keeling & Walker have developed a form of antimony tin oxide (ATO) that can replace ITO in many display applications. ITO is sold at $1,000 per kg, but ATO is less than $10 per kg!

Companies are also in the process of developing a complete range of materials, processes, equipments, and device designs necessary for emerging technologies such as OLED and flexible displays that will be manufactured on plastic and even paper substrates. The main differences between these new display technologies and existing mass production display technologies are that almost every process step can be performed using additive printing or other solution processable methods. All this will help next-generation displays to be more energy efficient in the manufacturing process.

Opportunities Aplenty
The low cost in setting up a manufacturing facility will allow more and more companies to enter into this manufacturing space. According to Williams, "Eventually, the production of flexible displays, and even flexible electronic systems (that can comprise of printed sensors, printed photovoltaic cell and battery, printed electronics and printed display) will result in a new era where local communities can organize and manufacture many of the devices and appliances in small volumes for their day to day living needs." He adds that in printing a device with its own power source (PV cell and battery) will mean that the device simply continues to work throughout its life without the need for a connection to the mains electricity or an external battery. "This will reduce the need to install massive power distribution infrastructure across a country and to every household, since the individual power needs are reduced," he says.

The Indian Picture
UK Trade and Investment, the lead UK Government organization which helps businesses locate in the UK and grow internationally, is helping UKDL to explore opportunities in emerging manufacturing destinations like India.

According to Williams, "We are in discussion with Videocon which is showing interest for their Plasma/TFT/LCD manufacturing unit. We are now preparing a much more detailed plan to present to Indian companies of the various display and lighting technologies that are available at UK. The Indian companies can then participate in a variety of business methods which include licensing, joint venture developments, or straight forward commercial transactions."

Sudesh Prasad
sudeshp@cybermedia.co.in

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