Good surface quality of plastic substrates is essential to reduce pixel defects during roll-to-roll fabrication of flexible
display active matrix backplanes. Standard polyimide substrates have a high density of "bumps" from fillers and belt
marks and other defects from dust and surface scratching. Some of these defects could be the source of shunts in
dielectrics. The gate dielectric must prevent shorts between the source/drain and the gate in the transistors, resist shorts in
the hold capacitor and stop shorts in the data/gate line crossovers in active matrix backplanes fabricated by self-aligned
imprint lithography (SAIL) roll-to-roll processes. Otherwise data and gate lines will become shorted creating line or
pixel defects. In this paper, we discuss the development of a proprietary UV curable planarization material that can be
coated by roll-to-roll processes. This material was engineered to have low shrinkage, excellent adhesion to polyimide,
high dry etch resistance, and great chemical and thermal stability. Results from PECVD deposition of an amorphous
silicon stack on the planarized polyimide and compatibility with roll-to-roll processes to fabricate active matrix
backplanes are also discussed. The effect of the planarization on defects in the stack, shunts in the dielectric and
curvature of finished arrays will also be described.
A low cost method and device for creating saddle stitch bound booklet documents is described. The device allows saddle stitch bound documents to be made using a unique low force method that avoids the issues and limitations found in commercial booklet making hardware. Typical commercial devices use high force industrial equipment that are physically bulky, unsafe, and expensive. The approach detailed here utilizes precision, light force, sheet-wise operations on individual sheets of paper to produce saddle stitch booklets, leveraging knowledge in precision paper handling and positioning. This method facilitates bound document creation with hardware that is compatible with common desktop and workgroup printer's sheet-at-a-time printing processes, but at a fraction of the cost of comparable commercial binding hardware. This platform enables the final part of the promise of desktop publishing.