The first thing that
strikes you about the NCD is its stark,
razor sharpness, with nearly black images on an almost
luminous, paper-white background. Text is easy to read
in most lighting conditions, with a contrast ratio of
6:1—and a brightness of at least 4 times that of an
LCD. It's that stunning white that sets the display
apart from an LCD. Nevertheless, the two display
technologies do share a few traits: they both have two
glass sheets, separated by a fluid-filled gap; they
therefore weigh about the same. From a commercial
perspective, the similarities mean that the two
technologies can be manufactured on almost entirely the
same equipment, hence at almost equal costs.
But in power consumption, there's no contest. NCDs
are power-frugal because of two factors. First, the high
contrast ratio eliminates the need for any kind of
separate lighting system, even when viewed in bright
sunlight. Second, unlike LCDs, NCDs do not need to be
constantly refreshed.
An LCD contains liquid-crystal molecules that are
sandwiched between two coated sheets of glass that are
polarized at 90 degrees to one another. The liquid
crystals have a natural twist that allows light to enter
one end and exit the other. By varying the electric
field through the display, the crystals are made to
untwist, blocking the passage of light. That creates
dark areas—pixels—on the display, for as long as the
voltage is maintained.
With an NCD, on the other hand, the principle
requires electrically charging a material to change its
color. Placing another charge-storing layer on the
second glass sheet as a source of charge for the
electrochromic material lets the image remain for as
long as several hours. This is because both plates
separately retain their opposite charges, in much the
same way as a capacitor retains its charge. To clear the
display, the voltage is reversed, sending the ions back
to the storage layer. Depending on the chemicals used
and the application, a new jolt of current may be needed
infrequently, from every 10 minutes to once an hour.
Basically, the display draws current only when the image
is changed.
Electrochromism has been known for decades; IBM, for
example, had a major development program in
electrochromic displays in the 1970s and early 1980s.
Bayer AG, in Leverkusen, Germany, also researched the
technology and was even awarded several patents, but it
also failed to make a practical display. Today, a number
of companies in Europe and the United States are still
trying to turn the phenomenon into products, including
Siemens, Aveso (a Dow Chemical spin-off), and Acreo.
All have been stymied by the limitations of
electrochromism. One of the most significant problems is
the delay needed to produce an optical change, one full
second or more. Because of this delay, electrochromic
applications have shown up only where the tint doesn't
need to change quickly—for example, in an automobile's
rear-view mirror. A number of cars today are equipped
with automatically darkening mirrors, which Gentex
Corp., of Zeeland, Mich., began selling to the
automotive industry in 1987. (The more commonly known
self-tinting sunglasses, for example, work by a
different process, called photochromism. Sunglasses are
coated with silver chloride or silver halide or
impregnated with a photosensitive compound that changes
chemically in the presence of ultraviolet light. The
molecules morph into a new shape that blocks more light.
That won't work for a rear-view mirror, because car
windows are themselves tinted to block UV.) By the
1990s, electrochromism started falling out of favor
among researchers looking to build the next big thing in
digital displays.
The Ntera
story actually begins in the early 1990s in a
laboratory in Switzerland. It was there, at the École
Polytechnique Fédérale de Lausanne (EPFL), that Donald
Fitzmaurice, a postdoctoral student from University
College Dublin, and Michael Graetzel, a professor in
EPFL's Institute of Chemical Sciences and Engineering,
began investigating how nanosized particles, placed in a
nanostructured film, retained many of the properties of
the film material used. The technique also created a
huge surface area, one that was the sum of the
individual nanoparticles' surface areas. The research
goal at the time was to build better solar cells. But
one day in 1991, Fitzmaurice noticed that these
nanostructured semiconductors darkened slightly when he
applied current. Exploiting this electrochromism, he
reasoned, would be useful in his research, because the
darkened areas would let him see the paths the electrons
were following through the nanostructures.
Fitzmaurice and Graetzel attached electrochromic
molecules to a film of semiconducting nanoparticles,
effectively creating a film that was many hundreds of
layers of electrochromic molecules thick. A charge
applied through the semiconducting particles caused the
molecules at the surface to be charged and therefore to
change color. Because the film was many layers of
particles thick, the optical change, barely detectable
in only one layer of particles, was surprisingly
dramatic. The two researchers immediately began thinking
of applications. Perhaps they had a better contender for
the rear-view mirror market, or could even realize the
longstanding goal of creating windows that changed tint,
making buildings more energy-efficient.
And then they realized that if they put a white layer
of film behind their device, they would have a
reflective, high-contrast display that had a wide
viewing angle, switched fairly quickly, and consumed
little power. For some uses, it would be darn near
perfect. "We thought we had a candidate for the
electronic paper market," Fitzmaurice says. "There were
electronic paper technologies out there, but there was
no clear winner."
Fitzmaurice finished his postdoc year in Lausanne and
returned to University College Dublin. He continued to
work with nanostructures and electrochromic materials
with a group of about 15 graduate students. The group
applied for two basic patents on the technology, and on
the basis of those patents in 1997, got a grant totaling
¤250 000 (about US $295 000) from the European Union to
set up a company to commercialize the technology.
Fitzmaurice hired David Corr, now Ntera's chief
technology officer, to run with the technology.
Fitzmaurice himself took an 18-month sabbatical in 2000
to work with Ntera full-time. That was also the time of
its first venture funding, from Cross Atlantic Capital
Partners, in Radnor, Pa. Some $35 million has been
poured into Ntera so far by Cross Atlantic and other
investors.
Moving such a new technology from the laboratory to
the marketplace isn't for the faint of heart. The
researchers had to find a good substance for the white
coating—the reflective layer. They settled on titanium
dioxide, which also whitens toothpaste and the coatings
on pills. (It's the active ingredient in many
sunscreens, too.) They adopted techniques such as
etching the glass substrate in order to group particles
into pixels. Their biggest hurdles, though, were
electrochemical.
Within the display, the two sheets of glass are
bonded together at their edges. The inner area between
them is filled with an electrolyte solution that
balances the charges on the two sheets. The
color-changing layer is attached to the piece of glass
that forms the front of the display. This layer is, at
heart, a film of titanium dioxide particles 15
nanometers in diameter—smaller than the wavelengths of
light and therefore transparent. The electrochromic
molecules are coated on each of the nanoparticles,
forming a layer a bit like the coating on a tennis ball.
The developers struggled to find the perfect
electrolyte—one that would help stabilize the system as
a whole. Ultimately, they found a suitable one, which
they won't identify; it is their most important trade
secret.
There were other challenges: they had to figure out a
way to protect the device from sunlight, which also
degraded the molecules. That problem was solved with a
UV-blocking film. Finally, they developed and patented
an electronic drive system and worked with display
manufacturers on the electronics that would switch each
pixel on or off.
Ntera's researchers had solved most of the
fundamental problems of the technology and could now
consider fabricating its first product on glass. While
Ntera's researchers worked on the design, the company's
founders, at the urging of their investors, narrowed
their market ambitions. They discarded color-changing
glass and mirrors, such as self-tinting windows, because
these were difficult markets for a small, new company to
break into. They also decided to defer pursuing e-books,
which would have required them to develop completely new
manufacturing equipment. That left them with the
low-information display business—a huge market that was
already well established and one whose existing plants
could be used with virtually no changes. "We realized
that with a judicious choice of materials and structure,
we could make this on a basic LCD line," Corr says.
Etching pixel patterns on the glass mimics the
analogous method in LCD manufacture, and the
screen-printing process is used in both manufacturing
schemes. LCD panels are then coated with a layer to
allow alignment of the liquid crystals, and NanoChromics
panels are dipped in a solution that contains the
electrochromic molecules, which attach themselves to the
semiconducting particles in the nanostructured titanium
dioxide film. In fact, would-be manufacturers of
electrochromic displays need to add just one piece of
equipment to their LCD setups: an oven, to bake the
nanoparticles that form the film. "We believe that we
can take an existing LCD manufacturing facility and
change it into an NCD producer for about $250 000," says
Ntera's CEO, Peter Ritz.
Ritz expects that in the long run, manufacturing NCDs
will prove to be cheaper than producing LCDs. For one
thing, NCDs have a greater tolerance for defects, and
therefore yields are expected to be higher.