TV Screens May Be Produced on Plastic Rolls

In the future, you may be able to roll up your televisionand put it in your coat pocket.

In such a scenario, electronic functions-wiring diagrams,actuators, sensors and antennae-are integrated in compact electronic modulesthat are produced on plastic film.

"Traditionally we just assembled pieces of electronics ontoa board and connected it up with wires. If you can convert that to aroll-to-roll printing process then all of your touch screens, all of your bigdisplay screens become much more economical to produce, "says PatrickW. Thomas, CEO of Bayer MaterialScience (BMS).

Polycarbonate films with printed electronic functions canalso be formed into three-dimensional shapes with the insert molding process.An example was on display at the K 2010 plastics fair in Dusseldorf, Germanylast month. The Bayer MaterialScience stand showed a large, one-piece centralconsole with integrated electronic features.

BMS is working on polymer electronics technologies in a newFunctional Films Research Center in Singapore.

They include:

"This printed polymer electronics technology is seen as anext-generation technology for delivering cost-effective production of highlyintegrated, complex molded electronic components," says Dirk Pophusen, head ofbusiness development for functional films in the Europe, Middle East, Africa,Latin America region at Bayer MaterialScience.

One of the technologies involved is a three-dimensional formablehardcoat film Makrofol HF. The basis for the film's excellent formability(including narrow radii and high depths of draw) is the curing approach. The scratch-resistantcoating is pre-cured and is not completely cured with standard UV lamps untilforming is finished.

BMS says the polycarbonate film produces surfaces with adeep gloss finish that are highly resistant to chemicals and abrasion. Onetarget use is a high-gloss piano finish in combination with "vanish-effect"technologies. These make the contours of light symbols appear to vanish whenthese are switched off. This is sometimes referred to as "blackpanel technology".

The electronics come from electrically activated plasticfilms, sometimes called artificialmuscles, which function as actuators and sensors. In a near-termapplication, they can produce a tactile response when a display is touched.They are described as largely wear-resistant, unlike conventional mechanicalbuttons.

One issue for the new polymer electronics is protection. Newcoatings and barrier systems are needed to shield the sensitive polymers. "Mostof the printed films that exist at the moment only really last for a shortperiod of time because air and water gets into the electronics and that destroysthese organic materials," says Thomas.

Roll-to-roll TV production may still be 10 to15 years away,but other, less dramatic applications, are closer.

According to forecasts by British market research companyIDTechEx, the global market for polymer electronics, is set to grow to almost$100 billion by 2020 and reach $250 billion just five years later.