CN104583853A - 用于生产电光显示器的工艺 - Google Patents
用于生产电光显示器的工艺 Download PDFInfo
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Abstract
通过以下来提供电光显示器的背板和前电极之间的电连接:形成前平面层压板(100),其依次包括透光导电层(104)、电光材料层(106)和层压粘合剂层(108);形成穿过前平面层压板(100)的所有三个层的孔(114);以及将可流动的导电材料(118)引入孔(114)中,可流动的导电材料(118)与透光导电层(104)进行电接触并延伸穿过粘合剂层(108)。
Description
相关申请
本申请涉及:
(a)美国专利No.6,982,178;7,236,292;7,443,571;7,729,039;8,068,272和8,077,381;
(b)美国专利No.7,733,554;
(c)美国专利No.7,910,175;
(d)美国专利No.7,583,427;以及
(e)美国专利No.7,843,624;8,034,209和8,390,301。
技术领域
本发明涉及用于生产电光显示器的工艺。本发明特别地但不排他地被用于包括封装电泳介质的显示器。然而,本发明还可以利用可以合并至机械连贯的多层薄膜中的各种其他类型的电光介质,诸如下述的封装液晶显示器和其他类型的电光显示器。
背景技术
作为应用于材料或者显示器的术语“电光”,其在此使用的是其在成像领域中的常规含义,指的是具有第一和第二显示状态的材料,该第一和第二显示状态的至少一个光学性质不同,通过向所述材料施加电场使该材料从其第一显示状态改变到第二显示状态。
术语“双稳态的”和“双稳定性”在此使用的是其在本领域中的常规含义,指的是包括具有第一和第二显示状态的显示元件的显示器,所述第一和第二显示状态的至少一个光学性质不同,从而在利用具有有限持续时间的寻址脉冲驱动任何给定元件以呈现其第一或第二显示状态之后,在该寻址脉冲终止后,该状态将持续的时间是改变该显示元件的状态所需的寻址脉冲的最小持续时间的至少几倍(例如至少4倍)。美国专利No.7,170,670表明,能够显示灰度的一些基于粒子的电泳显示器不仅可以稳定于其极端的黑色和白色状态,还可以稳定于其中间的灰色状态,一些其它类型的电光显示器也是如此。这种类型的显示器被恰当地称为是“多稳态的”而非双稳态的,但是为了方便,在此使用术语“双稳态的”以同时覆盖双稳态的和多稳态的显示器。
已知几种类型的电光显示器,例如:
(a)旋转双色构件类型,如例如在美国专利No.5,808,783;5,777,782;5,760,761;6,054,071;6,055,091;6,097,531;6,128,124;6,137,467;和6,147,791中所述;
(b)电致变色介质,例如纳米变色薄膜形式的电致变色介质,其包括至少部分由半导体金属氧化物形成的电极和附着到电极的能够进行可逆性颜色改变的多个染料分子;参见例如美国专利No.6,301,038;6,870,657;和6,950,220;以及
(c)电润湿显示器,如在Hayes,R.A.等,"Video-Speed ElectronicPaper Based on Electro wetting",Nature,425,383-385(2003)和美国专利No.7,420,549中描述。几种类型的电光显示器是公知的。
已经在许多年被作为密集研发的主题的一种类型的电光显示器是基于粒子的电泳显示器,其中,多个带电粒子在电场的影响下移动穿过流体。电泳显示器与液晶显示器相比,可以具有以下属性:良好的亮度和对比度、宽的视角、状态双稳定性、以及低功耗。然而,这些显示器的长期图像质量的问题阻止了它们的广泛使用。例如,组成电泳显示器的粒子易于沉降,导致这些显示器的使用寿命不足。
如上所述,电泳介质需要流体的存在。在大多数现有技术的电泳介质中,该流体是液态的,但电泳介质可以使用气态流体来产生;参见例如Kitamura,T.等,"Electrical toner movement for electronic paper-like display",IDW Japan,2001,Paper HCSl-1,以及Yamaguchi,Y.等,"Toner display usinginsulative particles charged triboelectrically",IDW Japan,2001,PaperAMD4-4。还参见美国专利No.7,321,459和7,236,291。这种基于气体的电泳介质当在允许粒子沉降的定向(例如在介质布置在垂直平面中时)上使用时,似乎会经历与基于液体的电泳介质相同类型的由于粒子沉降产生的问题。实际上,与在基于液体的电泳介质中相比,粒子沉降在基于气体的电泳介质中似乎是更严重的问题,这是由于气态悬浮流体的粘度与液体相比较低,允许电泳粒子的更快沉降。
授予或以麻省理工学院(MIT)和伊英克公司的名义的许多专利和申请描述了在封装电泳和其他电光介质中使用的各种技术。这种封装介质包括许多小囊体,每个囊体本身包括在流体介质中含有可电泳移动的粒子的内部相,以及围绕所述内部相的囊壁。通常,囊体本身保持在聚合粘合剂内以形成位于两个电极之间的连贯层。在这些专利和申请中描述的技术包括:
(a)电泳粒子、流体和流体添加物;参见例如美国专利No.7,002,728和7,679,814;
(b)囊体、粘合剂和封装工艺;参见例如美国专利No.6,922,276和7,411,719;
(c)含有电光材料的薄膜和子组件;参见例如美国专利No.6,825,829;6,982,178;7,236,292;7,443,571;7,513,813;7,561,324;7,636,191;7,649,666;7,728,811;7,729,039;7,791,782;7,839,564;7,843,621;7,843,624;8,034,209;8,068,272;8,077,381和8,177,942;以及美国专利申请公开No.2008/0309350;2009/0034057;2009/0109519;2009/0168067;2011/0032595;2011/0032396;2011/0075248;2011/0164301和2012/0176664;
(d)在显示器中使用的背板、粘合剂层和其他辅助层以及方法;参见例如美国专利No.7,116,318和7,535,624;
(e)颜色形成和颜色调整;参见例如美国专利No.7,075,502和美国专利申请公开No.2007/0109219;
(f)用于驱动显示器的方法;参见例如美国专利No.7,012,600和7,453,445;
(g)显示器的应用;参见例如美国专利No.7,312,784和8,009,348;以及
(h)非电泳显示器,如在美国专利No.6,241,921;6,950,220;7,420,549和8,319,759;以及美国专利申请公开No.2012/0293858中描述。
上述专利和申请中许多认识到在封装的电泳介质中包围离散的微囊体的壁可以被连续相替代,因此产生所谓的聚合物分散型电泳显示器,其中电泳介质包括电泳流体的多个离散微滴和聚合物材料的连续相,并且在这种聚合物分散型电泳显示器内的电泳流体的离散微滴可以被认为是囊体或者微囊体,即使离散囊体薄膜不与每个单独微滴相关联;参见例如上述美国专利No.6,866,760。因此,为了本申请的目的,这样的聚合物分散型电泳介质被认定为是封装的电泳介质的子类。
相关类型的电泳显示器是所谓的“微单元电泳显示器”,在微单元电泳显示器中,带电粒子和流体未封装在微囊体内,而是保持在形成于载体介质(通常是聚合物薄膜)内的多个空腔内。参见例如都授予Sipix Imaging公司的美国专利No.6,672,921和6,788,449。
虽然电泳介质通常是不透明的(因为,例如在很多电泳介质中,粒子基本上阻挡可见光透射通过显示器)并且在反射模式下工作,但许多电泳显示器可以制成在所谓的“快门模式”下工作,在该模式下,一种显示状态实质上是不透明的,而一种显示状态是透光的。参见例如美国专利No.5,872,552;6,130,774;6,144,361;6,172,798;6,271,823;6,225,971和6,184,856。类似于电泳显示器但是依赖于电场强度的变化的介电泳显示器可以在类似的模式下工作;参见美国专利No.4,418,346。其他类型的电光显示器也能够在快门模式下工作。在快门模式下工作的电光介质可以用于全色显示器的多层结构;在该结构中,邻近显示器的观察面的至少一层在快门模式下工作以暴露或隐藏更远离观察面的第二层。
封装的电泳显示器通常不受传统电泳装置的聚集和沉降故障模式的困扰并提供更多的有益效果,例如在多种柔性和刚性基板上印刷或涂布显示器的能力。(使用词“印刷”意于包括印刷和涂布的所有形式,包括,但不限于:诸如批量模具涂布、槽或挤压涂布、滑动或层叠涂布、幕式涂布的预先定量式涂布,诸如罗拉刮刀涂布、正向和反向辊式涂布的辊式涂布,凹面涂布,浸渍涂布,喷雾涂布,弯月面涂布,旋转涂布,刷涂,气刀涂布,丝网印刷工艺,静电印刷工艺,热印刷工艺,喷墨印刷工艺,电泳沉积(参见美国专利No.7,339,715),以及其他类似技术。)因此,所产生的显示器可以是柔性的。另外,因为显示器介质可以(使用多种方法)被印刷,所以显示器本身可以被便宜地制造。
其他类型的电光材料也可以用在本发明中。
电泳显示器通常包括电泳材料层和布置在电泳材料的相对侧面上的至少两个其他层,这两个层中的一个是电极层。在大多数这种显示器中,两个层都是电极层,并且电极层中的一个或两个被图案化以限定显示器的像素。例如,一个电极层可以被图案化成细长的行电极,并且另一电极层被图案化成与行电极垂直延伸的细长的列电极,像素由行和列电极的交叉点限定。可替换地,并且更通常地,一个电极层具有单一连续电极的形式,并且另一电极层被图案化成像素电极的矩阵,每个像素电极限定显示器的一个像素。在另一类型的电泳显示器中,其被用于与显示器分离的触笔、印刷头或类似的可移动电极,仅邻近电泳层的一个层包括电极,电泳层的相对侧面上的层通常是保护层,用于防止可移动电极损坏电泳层。
三层电泳显示器的制造通常涉及至少一个层压操作。例如,在上述MIT和伊英克的专利和申请中的几个中,描述了用于制造封装电泳显示器的工艺,其中,在粘合剂中包括囊体的封装电泳介质被涂布在柔性基板上,柔性基板在塑料薄膜上包括铟锡氧化物(ITO)或者类似的导电涂层(其用作最终显示器的一个电极),囊体/粘合剂涂层被干燥以形成牢固地附着至基板的电泳介质的连贯层。单独地,制备背板,其包含像素电极的阵列以及将像素电极连接至驱动电路的导体的合适配置。为了形成最终的显示器,使用层压粘合剂将其上具有囊体/粘合剂层的基板层压至背板。(可以使用非常类似的工艺来制备利用触笔或类似可移动电极的电泳显示器,其用诸如塑料薄膜的简单的保护层来代替背板,触笔或其他可移动电极可以在该保护层上滑动。)在该工艺的一个优选形式中,背板本身是柔性的,并且通过在塑料薄膜或其他柔性基板上印刷像素电极和导体来制备。用于通过该工艺批量生产显示器的显而易见的层压技术是使用层压粘合剂的辊式层压。
如在前述美国专利No.6,982,178中所述,在固态电光显示器中使用的许多部件、以及用于制造这种显示器的方法从在液晶显示器(LCD)中使用的技术中得到,液晶显示器当然也是电光显示器,尽管其使用液晶而非固态介质。例如,固态电光显示器可以利用透明基板上的包括晶体管或二极管的阵列和像素电极的相应阵列的有源矩阵背板,以及“连续的”前电极(从电极在多个像素上并且通常在整个显示器上延伸的意义上来说),这些部件实质上与在LCD中相同。然而,用于组装LCD的方法不能用于固态电光显示器。LCD通常通过以下来组装:在单独的玻璃基板上形成背板和前电极,之后粘着地将这些部件固定在一起,在它们之间留下小的孔,将所产生的组件放置在真空下,并且将组件浸没在液晶中,以使得液晶流经背板和前电极之间的孔。最后,液晶就位后,孔被密封以提供最终的显示器。
该LCD组装工艺不能容易地转用至固态电光显示器。因为电光材料是固态的,它必须在背板和前电极相互固定之前存在于这两者之间。此外,相比于简单地放置在前电极和背板之间而不用附接在任何一个的液晶材料,固态电光介质通常需要固定至前电极和背板二者;在大多数情况下,固态电光介质在前电极上形成,这是因为这通常比在包含电路的背板上形成介质更容易,以及之后通常通过利用粘合剂覆盖电光介质的整个表面并在热、压力和可能的真空下层压来将前电极/电光介质的组合层压至背板。
电光显示器通常是昂贵的;例如,在便携式计算机中的彩色LCD的成本通常是计算机的整体成本的主要部分。当电光显示器的使用扩展至比便携式计算机便宜得多的诸如移动电话和个人数字助理(PDA)的装置时,对于减少这种显示器的成本存在很大的压力。通过如上所述的在柔性基板上的印刷技术来形成一些固态电光介质的层的能力有可能通过使用用于生产涂布纸、聚合物薄膜和类似介质的商业设备利用诸如卷对卷涂布的批量生产技术来降低显示器的电光部件的成本。然而,这种设备是昂贵的,现在销售的电光介质的面积不足以使用专用设备,从而通常需要将涂布介质从商业涂布工厂运输至用于最终组装电光显示器的工厂,而不损坏电光介质的相对易碎的层。
前述美国专利No.6,982,178描述了很好地适用于批量生产的组装固态电光显示器(包括基于粒子的电泳显示器)的方法。本质上,该专利描述了所谓的“前平面层压板”(FPL),其依次包括透光的导电层、与导电层电接触的固态电光介质层、粘合剂层、以及释放片。通常,透光的导电层将被承载在透光基板上,透光基板优选为柔性的,在这种意义上,基板可以手动地围绕直径(例如)10英寸(254mm)的鼓缠绕,而没有永久的变形。术语“透光的”在该专利中使用并且在此是指由此指定的层传输足够的光以使得经由该层观看的观察者能够观察电光介质的显示状态的变化,其通常通过导电层和邻近的基板(如果存在的话)来观察。基板通常是聚合物薄膜,并且通常具有约1至约25密耳(25-634μm)、优选地约2至约10密耳(51-254μm)的范围的厚度。导电层便利地是例如铝或ITO的薄金属层,或者可以是导电聚合物。涂布有铝或ITO的聚(对苯二甲酸乙二醇酯)(PET)薄膜在商业上可得到,例如来自特拉华州威明顿市的杜邦公司的“镀铝的Mylar”(Mylar是注册商标),并且这种商业材料可以很好地用于前平面层压板。
使用这种前平面层压板的电光显示器的组装可以通过以下来实现:从前平面层压板移除释放片并且在有效地使得粘合剂层粘附至背板的条件下将粘合剂层与背板接触,从而将粘合剂层、电光介质层和导电层固定至背板。该工艺很好地适于批量生产,因为前平面层压板可以通常使用卷对卷涂布技术被批量生产,并且之后切割成需要用于特定背板的任意大小的片。
前述美国专利No.6,982,178还描述了用于在将前平面层压板安装至显示器之前测试前平面层压板中的电光介质的方法。在该测试方法中,释放片设置有导电层,并且足以改变电光介质的光学状态的电压被施加在该导电层和电光介质的相对侧面上的导电层之间。电光介质的观测之后揭露了介质中的任何故障,由此避免将故障的电光介质层压至显示器中,从而避免产生废弃整个显示器的成本,而不仅仅是故障的前平面层压板。
前述美国专利No.6,982,178还描述了用于测试前平面层压板中的电光介质的第二方法,其通过将静电电荷放置在释放片上,由此在电光介质上形成图像。该图像之后以与之前相同的方式被观察以检测电光介质中的任何故障。
前述美国专利No.7,561,324描述了所谓的“双释放膜”,其实质上是前述美国专利No.6,982,178的前平面层压板的简化版本。一种形式的双释放片包括夹在两个粘合剂层之间的一层固态电光介质,一个或多个粘合剂层由释放片覆盖。另一种形式的双释放片包括夹在两个释放片之间的一层固态电光介质。两种形式的双释放膜被用在基本上类似于用于从上述前平面层压板组装电光显示器的工艺但涉及两次单独的层压的工艺;通常,在第一次层压中,双释放片被层压至前电极以形成前子组件,并且之后在第二次层压中,前子组件被层压至背板以形成最终的显示器,但这两次层压的顺序可以根据需要反转。
前述美国专利No.7,839,564描述了所谓的“倒置前平面层压板”,其是前述美国专利No.6,982,178中描述的前平面层压板的变形。倒置前平面层压板依次包括透光保护层和透光导电层中至少之一、粘合剂层、固态电光介质层、以及释放片。该倒置前平面层压板用于形成在电光层和前电极或前基板之间具有层压粘合剂层的电光显示器,第二典型的薄的粘合剂层可以或可以不存在于电光层和背板之间。这种电光显示器可以将良好的分辨率和良好的低温性能相结合。
前述美国专利No.7,839,564还描述了设计用于使用倒置前平面层压板的电光显示器的大量制造的各种方法;这些方法的优选形式是“多重合并”方法,其被设计为允许一次层压用于多个电光显示器的部件。
前述美国专利No.6,982,178还描述了用于在前平面层压板被层压至的背板和前平面层压板内的透光导电层之间形成电连接的方法。如该专利的图21和22所示,前平面层压板内的电光介质层的形成可以被控制以留下不存在电光介质的未涂布区域(“中缝”),这些未涂布区域的部分之后可以用于形成必要的电连接。然而,从制造的观点来看,形成连接的该方法趋于是不期望的,这是因为连接的布置当然是背板设计的功能,从而涂布有特定布置的中缝的FPL仅可以用于一种或有限范围的背板,而为了节省的原因,期望仅生产可以用于任何背板的一种形式的FPL。
因此,前述美国专利No.6,982,178还描述了用于形成必要的电连接的方法,其通过在FPL的整个区域上涂布电光介质并且之后移除期望形成电连接处的电光介质。然而,这种电光介质的移除造成了其自己的问题。通常,电光介质必须通过使用溶剂或机械清除来移除,溶剂或机械清除会导致损坏或移除FPL的导电层(该导电层通常是小于1μm厚的金属氧化物层,例如铟锡氧化物),从而导致失败的电连接。在极端情况下,还可能对用于支撑和机械地保护导电层的前基板(通常是聚合物薄膜)造成损坏。在一些情况下,形成电光介质的材料可能不容易被溶化,并且必须使用腐蚀性的溶剂和/或高机械压力来移除,这样会恶化上述问题。
使用电光介质的选择性涂布和/或电光介质的选择性移除的类似方法也可以应用至上述的双释放膜和倒置前平面层压板。
通常实际上使用激光切割来从FPL的连续带分离适当大小的片以层压至单独的背板。这种激光切割也可以用于制备用于至背板的电连接的区域,其通过利用激光从层压粘合剂侧“轻触切割”FPL,以使得层压粘合剂和电光介质从连接区域移除,但是导电层未被移除。这种轻触切割需要精确控制激光功率和切割速度,从而薄的和相对易碎的导电层不被移除或损坏。此外,在轻触切割之后,通常需要机械地或化学地从导电层移除(“清除”)电光和/或粘合剂层的剩余部分以能够与该层进行良好的电接触。而且,根据连接的位置,导电层和相关前基板的弯曲可能使导电层破裂,从而使得背板和导电层之间的适当连接失败,从而导致显示失败。实际上,需要在清除步骤完成之后并且在FPL片被层压至背板之前检查每个FPL片。仅在FPL/背板层压之前,少量的导电粘合剂或墨水被放置在背板上将进行前电极连接的点处。在层压之后,导电粘合剂或墨水将前电极电连接至背板。通常,保护片随后被层压在显示器的观察面上,之后进行边缘密封操作以产生最终的显示模块。该工艺在用于显示器的批量生产时产生了可扩展性、产量和成本的问题。
前述美国专利No.7,733,554描述了不使用轻触切割(kiss cutting)的用于提供前电极和背板之间的电连接的两个工艺。在第一个所谓的“预形成的连接孔”或“PFCA”工艺中,首先形成包括层压粘合剂层和电光介质层的子组件。孔被切割贯穿该子组件,之后,透光电极层被固定至层压粘合剂层的暴露表面,电极层延伸越过孔。第二个所谓的“延伸的接片”工艺,其开始于形成包括层压粘合剂层和电光介质层的相同的子组件。然而,在延伸的接片工艺中,不形成穿过子组件的孔;而是,透光电极层被固定至子组件的层压粘合剂层的暴露表面,电极层具有延伸超出层压粘合剂和电光介质的层的***的接片部分。尽管这两个工艺避免了轻触切割前平面层压板的需要,但它们在大规模生产使用时具有其他实际缺点。两个工艺都需要在前电极固定至电光层之前知道(经由孔或接片的)前电极连接的位置;两个工艺都不允许采用以下方式的前平面层压板的大规模制造(通常通过卷对卷工艺),该方式允许前层压板被修改以生产各种不同尺寸的显示器,并由此需要不同的前平面层压板连接。
因此,需要形成对前平面层压板的导电层的电连接的改进的方法,并且本发明试图提供这种改进的方法。
发明内容
因此,本发明提供上述轻触切割工艺的修改。本发明的工艺使得轻触切割不是必要的;而是进行完全穿过FPL的切割以形成孔,之后可流动的导电材料被放置在孔中以提供背板与FPL的导电层之间的接触。
因此,本发明提供用于生产电光显示器的工艺,该工艺包括:
形成前平面层压板,其依次包括透光导电层、电光材料层和层压粘合剂层;
形成穿过前平面层压板的所有三个层的孔;以及
将可流动的导电材料引入孔中,可流动的导电材料与透光导电层进行电接触并延伸穿过粘合剂层。
为了方便,本发明的工艺之后可以被称为本发明的“贯穿切割”工艺。
术语“透光导电层”在此使用与上述美国专利No.6,982,178中相同的含义。该层应该是充分透光的,在电光层被切换时,经由透光导电层观察显示器的用户可以看到电光层的电光性质的改变。
在本发明的工艺中,前平面层压板可以包括覆盖层压粘合剂层的远离电光材料层的表面的释放片。孔可以或可以不延伸穿过该释放片,但通常最方便的是,孔延伸穿过释放片,从而前平面层压板的所有层可以在同一操作中被切割。如在前述美国专利No.6,982,178中所论述的,释放片可以包括导电层,其可以用于以已经描述的方式测试电光层。透光导电层可以承载在支撑层上;通常,导电层是前基板的一部分,前基板除了包括导电层以外,还包括支撑层,其通常为聚合物薄膜,其提供对通常相对易碎的电极层的机械支撑和保护。前平面层压板可以包括电光介质层的相对侧面上的两个层压粘合剂层,在这样的前平面层压板中,孔将延伸穿过两个层压粘合剂层。
本发明的工艺中孔的形成通常通过激光切割实现,为了以下更详细论述的原因,通常从前平面层压板的粘合剂层的那一侧实现。
在本工艺中生产的包含孔的前平面层压板可以以完全类似于在前述美国专利No.6,982,178中描述的通过电光介质和层压粘合剂的机械或溶剂移除而生产的包含孔的FPL的方式使用。由此,在移除释放片(如果有的话)之后,层压粘合剂可以被层压至包括至少一个电极的背板,可流动导电材料在该层压之前或期间被引入孔中以提供透光导电层和设置在背板上的触点之间的电连接。
附图说明
附图中的图1是本发明的工艺中使用的前平面层压板在形成贯穿该前平面层压板的孔之后的示意截面图。
图2示出被层压至背板的图1所示的前平面层压板。
具体实施方式
如上所述,本发明提供用于生产电光显示器的工艺。该工艺开始于前平面层压板,该前平面层压板依次包括透光导电层、电光材料层和层压粘合剂层。孔被贯穿前平面层压板的所有三个层形成,诸如导电粘合剂或导电墨水的可流动导电材料被引入孔中,以使得可流动材料与透光导电层电接触并延伸穿过粘合剂层。
现在将参考附图仅通过示意的方式更详细地描述本发明的优选工艺,附图是该工艺的两个不同阶段的前平面层压板(“FPL”,总地表示为100)的示意截面。附图不是按比例的,特别地,所示出的各个层的厚度为了容易示出而改变。
如已经提到的,附图中的图1是前平面层压板100在形成贯穿其的孔之后的示意截面图。FPL 100包括由聚(对苯二甲酸乙二醇酯)(PET)薄膜形成的透明前基板102、可以由铟锡氧化物(ITO)或导电聚合物形成的透光导电层104、电光材料层106(示出为封装电泳层)、粘合剂层108和释放片110,释放片110在其面向粘合剂层108的表面上设置有导电层112,导电层112可以便利地为薄的铝层。如图1所示,孔114通过从释放片侧指向PFL(即,如图1的箭头所示,向下)的激光切割器而被切割贯穿FPL的所有层。
如可以在图1中看出,经由贯穿FPL 100的孔114向下观察的观察者将看到孔114的底部附近暴露的导电层104的区域104a。孔切割工艺以两种方式暴露了导电层104的电极:1)在激光切割工艺期间,用于形成层102和104的PET/ITO薄膜熔化、蒸发和收缩,由此扩大了该孔;随着PET收缩或回烧,ITO层104被拉至通过切割工艺形成的圆柱中,其方式类似于在印刷电路板构造期间形成电镀通孔的方式;以及2)电光材料层106和层压粘合剂层108比PET/ITO回烧地更多,由此暴露附加的ITO层104。
图2示出被层压至背板116的图1所示的FPL 100。(请注意,图2中的FPL相对于图1的位置被倒置。)FPL首先使得释放片110及其附接导电层112移除。FPL之后放置在背板116附近,粘合剂层108与背板接触,可流动导电材料118(优选地导电粘合剂)分配至FPL中的孔中。可流动导电材料形成延伸穿过FPL中的孔的导电通路,其建立导电层104和设置在背板116上的电极120之间的电接触。FPL和背板116之后典型地穿过层压机(未示出)并在热和压力下被层压在一起。在该层压之后,保护片可以例如以前述美国专利No.6,982,178中描述的任何方式被层压在FPL上并且密封边缘。
当使用本发明的工艺时,前平面层压板的检查可以在FPL仍处于大的板或卷的形式时进行,以使得随后切割的FPL可被识别为适于使用。通常,该任务使用格网叠置片进行以识别较大的板或卷内的单个FPL。用于显示器的FPL的期望形状可以利用激光切割机以常规方式形成。
本发明可以允许消除在显示器制造期间对于片部分检查、轻触切割、释放片移除以及清除FPL的电光和粘合剂层的现有技术需求。这些工艺步骤可以替代为检查大的板或卷,在FPL的各个片被切割用于显示器的同时形成用于前电极连接的孔。这可以增大生产量并减少与清除和激光轻触切割有关的产量损失。另外,本发明的工艺应该使得制造加工成本和生产时间减少。
本发明可以允许减小当前用于创建顶部平面连接的FPL接片的尺寸,参见例如前述美国专利No.8,034,209。目前,对顶部平面连接尺寸的一个限制是需要技术人员的机械清除。使用激光在连接部位创建图案可以极大地增加给定切割区域的暴露导电层的量。例如,在1mm正方形中切割一系列紧密分组的平行线比相同面积的圆形孔提供更大的导电层暴露。图案密度是激光束焦点、机器的机械容差、以及用于支撑导电层的前基板的熔化特性的函数。
所暴露的导电层的量是可容易调节的,并且可以采用激光能够切割的任何形状,这可以是有用的特征,因为所需的电极触点的量随着显示器尺寸而改变。
本发明的另一技术优点是其可以允许使用利用当前化学和机械方法顶部平面不可清除的可替换电极材料。一些可替换电极材料对于当前清除工艺非常敏感,例如,聚-3,4-乙烯二氧噻吩(PEDOT)、可以用作导电层的导电聚合物容易被机械刮擦并使用溶剂损坏。
使用本发明的工艺生产的显示器中的电极配置可以是前述伊英克和MIT专利和申请中所述的任意类型。由此,例如,显示器可以是直接驱动类型,其中,背板设置有多个电极,每个电极设置有单独的连接器,控制器可以通过单独的连接器控制施加至特定电极的电压。在这种直接驱动显示器中,单一连续前电极通常被提供来覆盖整个显示器,但其他前电极配置也是可以的。根据所使用的电光材料的类型,可以使用无源矩阵驱动配置,其中(通常地)背板承载多个细长平行电极(“列电极”),而在电光材料的相对侧上,设置有与列电极垂直延伸的多个细长平行电极(“行电极”),一个特定列电极和一个特定行电极之间的重叠限定显示器的一个像素。本显示器还可以是有源矩阵类型,通常具有覆盖整个显示器的单一连续前电极和背板上的像素电极的矩阵,每个像素电极限定显示器的一个像素并具有相关联的晶体管或其他非线性元件,有源矩阵显示器以常规方式被扫描来以逐行方式写显示器。最后,本显示器还可以是触笔驱动类型,(通常地)在背板上具有单一电极,并且没有永久的前电极,显示器的写入通过在显示器的前表面上移动触笔来实现。
本发明的工艺可以利用上述任何类型的电光材料。由此,例如,前平面层压板中的电光材料可以包括旋转双色构件、电致变色或电润湿材料。可替换地,电光材料可以包括电泳材料,其包括设置在流体中并且能够在电场的影响下移动穿过流体的多个带电粒子。带电粒子和流体可以限制在多个囊体或微单元内,或者可以作为通过包括聚合物材料的连续相包围的多个离散微滴存在。流体可以为液态或气态。
Claims (15)
1.一种用于生产电光显示器的工艺,该工艺包括:
形成前平面层压板(100),其依次包括透光导电层(104)、电光材料层(106)和层压粘合剂层(108);
所述工艺的特征在于:
形成穿过所述前平面层压板(100)的所有三个层的孔(114);以及
将可流动的导电材料(118)引入所述孔(114)中,所述可流动的导电材料(118)与所述透光导电层(104)进行电接触并延伸穿过所述粘合剂层(108)。
2.根据权利要求1所述的工艺,其中,所述前平面层压板包括覆盖所述层压粘合剂层(108)的远离所述电光材料层(106)的表面的释放片(110)。
3.根据权利要求2所述的工艺,其中,所述释放片(110)包括导电层(112)。
4.根据权利要求2所述的工艺,其中,所述孔(114)延伸穿过所述释放片(110)。
5.根据权利要求1所述的工艺,其中,所述前平面层压板包括在所述电光介质层的相对侧面上的两个层压粘合剂层,所述孔延伸通过两个层压粘合剂层。
6.根据权利要求1所述的工艺,其中,所述孔(114)的形成通过激光切割来实现。
7.根据权利要求6所述的工艺,其中,所述激光切割从所述前平面层压板(100)的粘合剂层侧实现。
8.根据权利要求1所述的工艺,其中,所述导电材料(118)包括导电粘合剂或导电墨水。
9.根据权利要求2所述的工艺,还包括从所述前平面层压板(100)移除所述释放片(110);以及
将所述前平面层压板的剩余层层压至包括至少一个电极的背板(116),
其中,在所述层压之前或期间将所述可流动的导电材料(118)引入所述孔(114)中以提供所述透光导电层(104)和设置在所述背板(116)上的触点之间的电连接。
10.根据权利要求9所述的工艺,还包括在所述前平面层压板被层压至所述背板之后,将保护片层压在所述前平面层压板上。
11.根据权利要求1所述的工艺,其中,所述电光材料包括旋转双色构件、电致变色或电润湿材料。
12.根据权利要求1所述的工艺,其中,所述电光材料包括电泳材料,其包括设置在流体中并能够在电场的影响下移动穿过所述流体的多个带电粒子。
13.根据权利要求12所述的工艺,其中,所述带电粒子和所述流体被限制在多个囊体或微单元内。
14.根据权利要求12所述的工艺,其中,所述带电粒子和所述流体作为通过包括聚合物材料的连续相包围的多个离散微滴存在。
15.根据权利要求12所述的工艺,其中,所述流体是气态的。
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CN104583853B (zh) | 2018-01-26 |
US20160103380A1 (en) | 2016-04-14 |
HK1206820A1 (zh) | 2016-01-15 |
US9238340B2 (en) | 2016-01-19 |
EP2877895A1 (en) | 2015-06-03 |
US20140027044A1 (en) | 2014-01-30 |
US11022854B2 (en) | 2021-06-01 |
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US10466564B2 (en) | 2019-11-05 |
EP2877895B1 (en) | 2017-09-06 |
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US20200064705A1 (en) | 2020-02-27 |
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