Corning's LCD Story Technology, Leadership and Change Part II

From Novelty to Ubiquity: Challenges & Strategies of

Scaling the LCD Platform

Dr. Peter Bocko CTO – Corning Glass Technologies ARPA-E Workshop on Micro-PV 8 May 2014

Glass Technologies © Corning Incorporated 2014 2

What is an active matrix LCD? What product did

Corning sell?

External Use

Authorized Labels :

Applied Materials Confidential.

Applied Materials Confidential

Restricted/Modifier

Applied Materials

Confidential/Modifier

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3

TFT-LCD Panel Manufacturing

Liquid

Crystal

Source: Display Search, Applied Materials

Color Filter

PVD

Array PVD

PECVD

Array Tester


Mid-1980’s – First commercial active matrix LCD devices

• Corning supplies substrates for

company’s first commercial

active matrix LCD product

• 3-inch TV made by Matsushita

(known commercially as

Panasonic) debuts in 1986


LCDs are ubiquitous today based upon the versatility

of the platform

>100”


LCD platform success, far from assured in the late 80’s, is

evidenced by 2013 substrate consumption of over 4 B ft²

0

500

1000

1500

2000

2500

3000

3500

4000

4500

1987 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

Millio

n S

qu

are

Feet


Cumulatively…about 24 billion square feet of high-spec

glass have been consumed by the LCD industry since 1987

This is enough

glass to create a

continuous ring

of 100” LCD TVs

circling the earth

and the moon

//upload.wikimedia.org/wikipedia/commons/2/22/Earth_Western_Hemisphere_transparent_background.png

//upload.wikimedia.org/wikipedia/commons/e/e1/FullMoon2010.jpg


The LCD glass demand developed through three

successive waves of application growth

0

500

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3500

4000

'97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12

TV

Monitor

Mobile PC

Small

Millio

n S

qu

are

Feet

viability

notebook

computer

practicality

desktop

monitor

ubiquity via versatility

TV + everything else


Glass is just one component in the LCD value chain Our recipe for 20 years of sustained value

Advanced optical melting +

fusion sheet forming process

Fusion

Isopipe

Molten glass

Sheet of glass

Flat Stable

Clean

Innovative aluminosilicate

glass compositions


LCD commercialization (approx. ‘89-’94) proved viability of the

LCD platform via the notebook application

0

500

1000

1500

2000

2500

3000

3500

4000

'97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12

TV

Monitor

Mobile PC

Small

Millio

n S

qu

are

Feet

viability

LCD’s key attributes relevant to

NBs: Thin, light, color & high

resolution capable, low voltage

operation (runs on batteries)


Understanding the core of glass value: What enabled

scale was surface

Ground/Polished As Formed

ca. 1997 competitor

polished glass Corning code 7059 non-

polish glass


Early learning was that the finest sub-micron scratch

can result in yield loss


0

500

1000

1500

2000

2500

3000

3500

4000

'97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12

TV

Monitor

Mobile PC

Small

Millio

n S

qu

are

Feet

From 1995 – 2002 the LCD proved practicality by

displacing CRTs in the computer monitor application

practicality

LCD’s key attributes relevant to

CRT displacement in monitors:

Flat & scalable to larger sizes,

green, non-fatiguing viewing

(crisp digital screen)


0

500

1000

1500

2000

2500

3000

3500

4000

'97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12

TV

Monitor

Mobile PC

Small

Millio

n S

qu

are

Feet

LCD Ubiquity: 2003 - Present

ubiquity via versatility

LCD’s key to winning the display space

is based upon the versatility of LCD & its

technology extensions. The “legacy”

performance issues are neutralized at

the same time the platform is scaled.


Scaling the LCD substrate area: 100X

Year

2009

2006

2005

2004

2003

2002

2000

1995

1993

Gen 8

Gen 7

Gen 6

Gen 7.5

Gen 10

Gen 5

Gen 4

Gen 3

Gen 2

LCD TV

Information Technology

Substrate Generations

typical size

used in LCD

pilot line in

mid-80’s

3.1meters

2.9 meters

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cost per area

LCD

Source: Display Search, Nikkei BP, Applied Materials

1999 2008

0.62 x 0.75m ~3 x 3m

$10,000/m2 $1,190/m2

1 million m2 84 million m2

cost per watt

SOLAR

Source: SIA, In-Stat, IC Insights

IC

cost per transistor

Above data for DRAM

16

Exponential Growth Industries Where Technology enables Demand

1980 1994

3µm 0.35µm

~$330/Mb ~$3/Mb

~3X1012 bits ~7X1015 bits

2008 ?

c-Si c-Si/TF/Other

~$4/Wp module $1-2/Wp module

~5GW >50GW

Source: Applied Materials

AKT PECVD System Family for Flat Panel Display Manufacturing

AKT-1600B CVD

< 400 x 500 mm

AKT-3500 CVD, AKT-4300 CVD

< 620 x 750 mm

1000x1000㎟Class

“Gen 5”

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AKT-90K PECVD (Gen 10) System Overview

Triple Slot Load Lock

Transfer Chamber w/ Dual-arm

Vacuum Robot

AKT-APX™

Process Chamber (x5)

Foot print: ~14m x 14m | Weight: 273 metric tons

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Equipment Cost Per Glass Area ($/m2)

Dramatic Improvement with Larger Substrates

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20

0

4

8

12

1993 1995 1997 1999 2001 2003 2005 2007 2009 2011F F

Su

bs

tra

te A

rea

(M

2)

$100

$10

$1

Co

st p

er A

rea

($

Th

ou

sa

nd/m

2)

Glass Size Migration – Driving Cost Reduction

Gen 2 Gen 3 Gen 4

Gen 5

Gen 6

Gen 7

Gen 8 Gen 8.5

Gen 10

Generation Scaling and Cost Reduction Key to Growth

Cost Reduction

Demand

Scale + Technology

Gen 2 Gen 5 Gen 8.5

Substrate 400 x 500mm 1.1 x 1.3m 2.2 x 2.5m

Application Notebook PC PC Monitor LCD TV

# of panels 10.4” x 4 22” x 8 46” x 8


Rendering is of Sharp’s Manufacturing Complex for the 21st Century, located in Sakai City, Japan.

Sharp

Corning

The terminal Gen Platform: Sharp’s Gen 10 “Green

Front Sakai” brought LCD to 3 meter scale

Original concept of fully built out complex


The terminal Gen Platform: Sharp’s Gen 10 “Green Front

Sakai”

• Facility is the first of its kind in the display industry

– Corning is on of 19 companies on site: mutual benefits in logistics, inventory and quality

• Complex is 314 acres, the equivalent of 240 football fields

• Environmentally advanced production

• Panel production capacity:

– At full capacity, capable of over

1 million 40” LCD panels/month


Gen 10 efficiently produces wide range of panel sizes

Six Panels

70–inch class

Eight Panels

60–inch class

Panel Size Gen 10 Gen 8

Panel Number Panel Number

70–inch class 6 2

60–inch class 8 3

40–inch class 18 8

Comparison of Panelization: Gen 10 vs. Gen 8

Eighteen

Panels

40–inch class


Corning moves Gen 10 glass directly into Sharp’s process

Sharp’s inter-building transport system moves Gen 10 substrates directly to production floor, eliminating traditional delivery systems. Previously, transportation infrastructure has limited glass substrate size


Is there a Moore’s Law for Display? Kind of…

Pixel Structure in Large Screen LCD-TV

Pixel Structure in High Resolution

Smart Phone

Large mother glass used for

multiplicity of display panels Higher resolution in small &

intermediate mobile devices


Resolution trend: Moore’s Law for LCD manufacture

10

100

1000

10000

100000

1000000

1980 1985 1990 1995 2000 2005 2010 2015

Pix

els

/Su

bs

tra

te x

10

³

Year

Gen 8 LCD- TV

fabs used for

mobile devices ...

Almost 1 Billion

Pixels per Mother

Glass!


This brings us up to the present…

LCD platform is continuing to grow…abundant opportunities for

extending display functionality & performance…so the scaling of the

LCD platform is a great success story, right?

WRONG! (for the participants…great for the consumer)

• LCD platform looks like a 25 year suicide pack for

display manufacturers characterized by hyper-

competition, over investment, periodic non-profitability

but requiring sustained investment for product

differentiation with poor return.

• The glass manufacturer remains the last material

component supplier standing in terms of sustained

value capture…but the pressure is ratcheted up

continually.

28 © Corning Incorporated 2014 Corning Incorporated

One of the negative aspects of the economics of

scaling LCD has been nationalism

1 1990

2

1995

3 1997

4 2000


Flexible glass is an enabling technology that supports

key trends in display devices & future breakthroughs



Thin and flexible glass substrates for ultra-slim displays with

promise for ultra-low-cost manufacture

• Corning® Willow ® Glass is thin enough to be

flexible while retaining its superior glass

attributes

• Combines inherent benefits of glass with a

mechanically bendable form factor, enabling

continuous and cost-efficient processing

• Enables thinner, lighter, and potentially

conformable electronic devices that deliver

high performance at a lower cost

• Eventually, displays will be printed on a

flexible web…but years of development are

required to make this practical.


Flexible glass applications roadmap – optimistically

viewed in 2011 – delayed largely by lack of ecosystem Next-generation technologies

E-Paper Flexible display

Organic PV OLED lighting

Roll-to-roll displays

2010 2011 2012 2014 2015 2013

Initial commercial products

OLED or LCD Color Filter

ProCap Touch Sensor

Flexible CIGS PV panels

Lab-scale device demos

University of Stuttgart TFT-LCD

ITRI-DTC Ch-LC display

HP Oxide TFTs

WMU / CAMM Organic PV


My conclusions

• The scaling of LCD technology was effected through waves of application growth.

• Two of the key technologies that enabled this scaling were engineered glass substrates and PECVD/PVD platforms.

• Despite a successful technological scaling & innovation that neutralized LCD’s legacy performance issues, it has been a poor economic venture for panel makers and some brands.

– Nationalism and tardy rationalization of manufacturing capacity has led to periodic over-supply and a pathological market dynamics.

– Good for consumer…bad for many in the LCD value chain.

• The emergence of R2R manufacture, initially for display & lighting components, may be attractive for new applications such as micro PV.

Documents

Corning's LCD Story Technology, Leadership and Change Part II