Electroluminescent system and process

Abstract

A system and method for producing a conformal electroluminescent coating on an object wherein an electrically conductive base backplane film layer is applied upon a substrate. One or more intermediate layers, such as dielectric, or phosphor film layers, is/are applied upon the conductive backplane film layer. An electrode film layer is applied upon the one or more intermediate layers using a substantially transparent, electrically conductive material. The electroluminescent phosphor is excitable by an electrical field established across the phosphor film layer such that the device emits electroluminescent light upon application of an electrical charge between the conductive backplane film layer and the electrode film layer.

Claims

1. A conformal coating comprising: an inherently conductive and substantially transparent outer layer comprising 2-12% by weight of an outer layer conductive component, 55-80% by weight of a reducer solvent component to assist in the deposition and post-deposition flow of the outer layer and 10-30% by weight of a film-forming binder component that forms a film that flows evenly and consistently when atomized onto the surface of an object; an inherently conductive inner layer comprising 40-75% by weight of said reducer solvent component, 20-35% by weight of said binder component, 20-50% by weight of an inner layer conductive component; a first intermediate layer, being disposed between the inner and outer layers, and further comprising, 45-80% by weight of said reducer solvent component, 10-35% by weight of said binder component, 20-50% by weight of a high-dielectric pigment component, said first intermediate layer being adapted to insulate said outer layer from said inner layer, where the film flows to a smooth film that completely covers the inner layer so as not to allow a direct electrical connection between conductive layers; a second intermediate layer, being disposed between the inner and outer layers, and further comprising 40-80% by weight of said reducer solvent component, 10-35% by weight of said binder component, 20-50% by weight of an electroluminescent pigment component, said second intermediate layer being adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized.

2. A conformal coating comprising: an inherently conductive and substantially transparent outer layer comprising 2-12% by weight of an outer layer conductive component, 55-80% by weight of a reducer solvent component to assist in the deposition and post-deposition flow of the outer layer, said reducer solvent component including any one or more of, toluene, xylene, acetone, naphtha, mineral spirits, methyl ethyl ketone, acetone, water, ethanol, isopropyl alcohol, n-butyl alcohol, methanol, ethyl benzene, cumene, n-propyl acetate, methyl acetate, methyl cyclohexane, p-Trifluoromethylphenyl chloride, and p-Chlorobenzotrifluoride, or other volatile solvent, and 10-30% by weight of a film-forming binder component that forms a film that flows evenly and consistently when atomized onto the surface of an object, said outer layer having a thickness in the range of 0.0002″ to 0.0006″, said outer layer having a resistivity of less than 2000 ohm/square meter; an inherently conductive inner layer comprising 40-75% by weight of said reducer solvent component, 20-35% by weight of said binder component, 20-50% by weight of an inner layer conductive component said inner layer having a thickness in the range of 0.0005″ to 0.002″; said inner layer having a resistivity of less than 20 ohm/square meter; a first intermediate layer, being disposed between the inner and outer layers, and further comprising 45-80% by weight of said reducer solvent component, 10-35% by weight of said binder component, 20-50% by weight of a high-dielectric pigment component, said high-dielectric pigment component including any one or more of barium titanate, strontium titanate, titanium dioxide, lead zirconate titanate, tantalum oxide, aluminum oxide, or other high-dielectric solids, said first intermediate layer having a thickness in the range of 0.0005″ to 0.002″, said first intermediate layer being adapted to insulate said outer layer from said inner layer, where the film flows to a smooth film that completely covers the inner layer so as not to allow a direct electrical connection between conductive layers; a second intermediate layer, being disposed between the inner and outer layers, and further comprising 40-80% by weight of said reducer solvent component, 10-35% by weight of said binder component, 20-50% by weight of an electroluminescent pigment component, said electroluminescent pigment component including any one or more of metal-doped zinc sulfide phosphors, metal-doped zinc selenide phosphors, metal-doped or native crystalline oxides or oxide phosphors of Sr, Ga, Ba, and Eu in some combination, or other electroluminescent phosphors, said second intermediate layer being adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized.

3. The conformal coating of claim 2 further comprising: said outer layer conductive component comprises a conductive pigment component; said inner layer conductive component comprises an inherently conductive polymer component.

4. The conformal coating of claim 2 further comprising: said outer layer conductive component comprises a conductive pigment component; said inner layer conductive component comprises an at least partially transparent conductive pigment component.

5. The conformal coating of claim 2 further comprising: said outer layer conductive component comprises an inherently conductive polymer component; said inner layer conductive component comprises a conductive pigment component.

6. The conformal coating of claim 2 further comprising: said outer layer conductive component comprises an at least partially transparent conductive pigment component; said inner layer conductive component comprises a conductive pigment component.

7. The conformal coating of claim 2 further comprising: the film-forming binder component being compatible with an inherently conductive polymer component; the reducer solvent component being functionally compatible with, the film-forming binder component, and the inherently conductive polymer component.

8. The conformal coating of claim 2 further comprising: the film-forming binder component being compatible with a conductive at least partially transparent pigment component; the reducer solvent component being functionally compatible with, the film-forming binder component, and the conductive at least partially transparent pigment component.

9. The conformal coating of claim 2 further comprising: said binder component of said inner layer further comprising an acrylic or a polyurethane.

10. The conformal coating of claim 2 further comprising: said binder component of said first intermediate layer being acrylic or a polyurethane.

11. The conformal coating of claim 2 further comprising: said binder component of said second intermediate layer being an acrylic or a polyurethane.

12. The conformal coating of claim 2 further comprising: said first intermediate layer being disposed between said inner layer and said second intermediate layer; said second intermediate layer being disposed between said outer layer and said first intermediate layer.

13. The conformal coating of claim 2 further comprising: said first intermediate layer and said second intermediate layer are blended into a combined intermediate layer and sprayed simultaneously; said combined intermediate layer being adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized, and where the film flows to a smooth film that completely covers the inner layer so as not to allow a direct electrical connection between conductive layers; said reducer solvent component of said combined intermediate layer comprising an acrylic.

14. The conformal coating of claim 2 wherein: the reducer solvent component of the inherently conductive and substantially transparent outer layer comprises, 15-%30% by weight ethanol, 15-25% by weight methyl acetate, 15-25% by weight p-Chlorobenzotrifluoride, and 15-25% by weight water.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features of the inventive embodiments will become apparent to those skilled in the art to which the embodiments relate from reading the specification and claims with reference to the accompanying drawings, in which:

(2) FIG. 1 is a schematic layer diagram of an EL lamp according to one embodiment of the present invention.

(3) FIG. 2 is a schematic layer diagram of an EL lamp according to another embodiment of the present invention.

(4) FIG. 3 is a schematic layer diagram of an EL lamp according to yet another embodiment of the present invention.

DETAILED DESCRIPTION

(5) In the discussion that follows, like reference numerals are used to refer to like elements and structures in the various figures. Also, the terms “transparent” and “clear” generally refer to a layered material's ability to allow light to pass through without significant absorption and includes translucent characteristics. For the purpose of discussion, as used herein the terms “film”, “layer” and “coating” are used interchangeably to describe an applied layer of material in an EL device.

(6) While this invention has been shown and described with respect to detailed embodiments thereof, it will be understood by those skilled in the art that changes in form and detail thereof may be made without departing from the scope of the claims of the inventions.

(7) In one embodiment, a spray-applied conformal coating 920 comprises, inherently conductive and substantially transparent outer layer 460 comprising 2-12% by weight of an outer layer conductive component, 55-80% by weight of a reducer solvent component to assist in the deposition and post-deposition flow of outer layer 460 and 10-30% by weight of a film-forming binder component that forms a film that flows evenly and consistently when atomized onto the surface of an object; an inherently conductive inner layer 400 comprising 40-75% by weight of the reducer solvent component, 20-35% by weight of the binder component, 20-50% by weight of an inner layer conductive component; a first intermediate layer 420, being disposed between the inner and outer layers 400, 460, and further comprising, 45-80% by weight of the reducer solvent component, 10-35% by weight of the binder component, 20-50% by weight of a high-dielectric pigment component, the high-dielectric pigment component, the first intermediate layer 420 being adapted to insulate the outer layer 460 from the inner layer 400, where the film flows to a smooth film that completely covers inner layer 400 so as not to allow a direct electrical connection between conductive layers 400, 460; a second intermediate layer 440, being disposed between the inner and outer layers 400, 460, and further comprising 40-80% by weight of the reducer solvent component, 10-35% by weight of the binder component, 20-50% by weight of an electroluminescent pigment component, the second intermediate layer 460 being adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized.

(8) In one embodiment, a spray-applied conformal coating 920 comprises, inherently conductive and substantially transparent outer layer 460 comprising 2-12% by weight of an outer layer conductive component, 55-80% by weight of a reducer solvent component to assist in the deposition and post-deposition flow of outer layer 460, the reducer solvent component including any one or more of, toluene, xylene, acetone, naphtha, mineral spirits, methyl ethyl ketone, acetone, water, ethanol, isopropyl alcohol, n-butyl alcohol, methanol, ethyl benzene, cumene, Solane, n-propyl acetate, methyl acetate, methyl cyclohexane, p-Trifluoromethylphenyl chloride, and p-Chlorobenzotrifluoride, or other volatile solvent, typically in the ratio of 15-%30% by weight ethanol, 15-25% by weight methyl acetate, 15-25% by weight p-Chlorobenzotrifluoride, and 15-25% by weight water and 10-30% by weight of a film-forming binder component that forms a film that flows evenly and consistently when atomized onto the surface of an object, outer layer 460 having a thickness in the range of 0.0002″ to 0.0006″, outer layer 460 having a resistivity of less than 2000 ohm/square meter; inherently conductive inner layer 400 comprises 40-75% by weight of the reducer solvent component, 20-35% by weight of the binder component, 20-50% by weight of an inner layer conductive component inner layer 400 having a thickness in the range of 0.0005″ to 0.002″; outer layer 460 having a resistivity of less than 20 ohm/square meter; first intermediate layer 420, is disposed between inner and outer layers 400, 460, and further comprises 45-80% by weight of the reducer solvent component, 10-35% by weight of the binder component, 20-50% by weight of a high-dielectric pigment component, the high-dielectric pigment component including any one or more of barium titanate, strontium titanate, titanium dioxide, lead zirconate titanate, tantalum oxide, aluminum oxide, or other high-dielectric solids, first intermediate layer 420 having a thickness in the range of 0.0005″ to 0.002″, first intermediate layer 420 is adapted to insulate outer layer 460 from inner layer 400, where the film flows to a smooth film that completely covers the inner layer so as not to allow a direct electrical connection between conductive layers 400, 460; second intermediate layer 440, is disposed between inner and outer layers 400, 460, and further comprises 40-80% by weight of the reducer solvent component, 10-35% by weight of the binder component, 20-50% by weight of an electroluminescent pigment component, the electroluminescent pigment component including any one or more of metal-doped zinc sulfide phosphors, metal-doped zinc selenide phosphors, metal-doped or native crystalline oxides such as Ga2O3, ZnGa2O4, CaGa2O4, Zn2SiO7, Zn2SiO4, Y2SIO5, and oxide phosphors of Sr, Ga, Ba, and Eu in some combination, or other electroluminescent phosphors, second intermediate layer 440 is adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized.

(9) In one embodiment, the outer layer conductive component comprises a conductive pigment component; the inner layer conductive component comprises an inherently conductive polymer component.

(10) In one embodiment, the inherently conductive polymer component comprises PEDOT:PSS; the conductive pigment component includes any one or more of silver flakes, silver nanowire, silver nanoparticles, copper flakes, copper nanowire, copper nanoparticles, nickel flakes, nickel nanowire, nickel nanoparticles, silver-coated copper flakes, silver-coated copper nanowire, carbon nanotubes, graphene, metal-coated particles, or other inherently conductive particles, typically silver flakes or silver-coated copper flakes.

(11) In one embodiment, the outer layer conductive component comprises an inherently conductive polymer component; the inner layer conductive component comprises a conductive pigment component.

(12) In one embodiment, the inherently conductive polymer component comprises PEDOT:PSS; the conductive pigment component includes any one or more of silver flakes, silver nanowire, silver nanoparticles, copper flakes, copper nanowire, copper nanoparticles, nickel flakes, nickel nanowire, nickel nanoparticles, silver-coated copper flakes, silver-coated copper nanowire, carbon nanotubes, graphene, metal-coated particles, or other inherently conductive particles, typically silver flakes or silver-coated copper flakes.

(13) In one embodiment, the film-forming binder component is compatible with an inherently conductive polymer component; the reducer solvent component is functionally compatible with, the film-forming binder component, and the inherently conductive polymer component.

(14) In one embodiment, outer layer 460 further comprises 3%-5% by weight of the outer layer conductive component.

(15) In one embodiment, outer layer further 460 comprises 70-75% by weight of the reducer solvent component.

(16) In one embodiment, the binder component of outer layer 460 including any one or more of an acrylic, polyurethane, vinyl, latex, cellulose acetate butyrate or other binder, preferably a polyurethane or acrylic.

(17) In one embodiment, outer layer 460 further comprises 10-15% by weight of the film-forming binder component.

(18) In one embodiment, outer layer 460 has a thickness of substantially 0.0005″.

(19) In one embodiment, the reducer solvent component of inner layer 400 further comprises 50-70% n-butyl acetate and 30-50% xylene.

(20) In one embodiment, the reducer solvent component of inner layer 400 further comprises or 50-70% methyl acetate and 30-50% xylene.

(21) In one embodiment, inherently conductive inner layer 400 further comprises 55%-65% by weight of the reducer solvent component.

(22) In one embodiment, inner layer 400 further comprises 20-25% by weight of the binder component.

(23) In one embodiment, the binder component of inner layer 400 further comprises an acrylic.

(24) In one embodiment, the binder component of inner layer 400 further comprises a polyurethane.

(25) In one embodiment, inner layer 400 further comprises 30%-40% by weight of the inner layer conductive component.

(26) In one embodiment, inner layer 400 has a thickness of substantially 0.001″.

(27) In one embodiment, the reducer solvent component of first intermediate layer 420 is 50-70% n-butyl acetate and 30-50% xylene.

(28) In one embodiment, the reducer solvent component of first intermediate layer 420 is 50-70% methyl acetate and 30-50% xylene.

(29) In one embodiment, first intermediate layer 420 further comprises 60%-65% by weight of the reducer solvent component.

(30) In one embodiment, first intermediate layer 420 further comprises 15-20% by weight of the binder component.

(31) In one embodiment, the binder component of first intermediate layer 420 is acrylic.

(32) In one embodiment, the binder component of first intermediate layer 420 is polyurethane.

(33) In one embodiment, first intermediate layer 420 further comprises 35%-45% by weight of the high-dielectric pigment component.

(34) In one embodiment, first intermediate layer 420 has a thickness of substantially 0.001″.

(35) In one embodiment, the reducer solvent component of second intermediate layer 440 is 50-70% n-butyl acetate and 30-50% xylene.

(36) In one embodiment, the reducer solvent component of second intermediate layer 440 is 50-70% methyl acetate and 30-50% xylene.

(37) In one embodiment, second intermediate layer 440 further comprises 60%-65% by weight of the reducer solvent component.

(38) In one embodiment, second intermediate layer 440 further comprises 15-20% by weight of the binder component.

(39) In one embodiment, the binder component of second intermediate layer 440 is an acrylic.

(40) In one embodiment, the binder component of second intermediate layer 440 is a polyurethane.

(41) In one embodiment, second intermediate layer 440 further comprises 35%-45% by weight of an electroluminescent pigment component.

(42) In one embodiment, the electroluminescent pigment component has a thickness of substantially 0.002″.

(43) In one embodiment, the electroluminescent pigment component of second intermediate layer 440 has a thickness of substantially 0.002″.

(44) In one embodiment, outer layer 460 has a thickness in the range of 0.001″ to 0.002″ outer layer 460 has a resistivity of less than 100 ohm/square meter.

(45) In one embodiment, inner layer 400 has a thickness in the range of 0.0002″ to 0.001″ inner layer 400 has a resistivity of less than 2000 ohm/square meter.

(46) In one embodiment (FIG. 1), first intermediate layer 420 is disposed between inner layer 400 and second intermediate layer 440, and second intermediate layer 440 is disposed between outer layer 460 and first intermediate layer 420.

(47) In one embodiment (FIG. 3), first intermediate layer 420 and second intermediate layer 440 are blended into combined intermediate layer 441 and sprayed simultaneously; combined intermediate layer 441 comprises, 40-80% by weight of the reducer solvent component, 10-35% by weight of the binder component, 10-30% by weight of an electroluminescent pigment component, 10-25% by weight of a high-dielectric pigment component, combined intermediate layer 441 has a thickness in the range of 0.002″ to 0.004″, combined intermediate layer 441 is adapted to flow after deposition in a manner where the electroluminescent pigment is dispersed in an even and uniform layer as the film cures to provide a uniform lighting effect when energized, and where the film flows to a smooth film that completely covers inner layer 400 so as not to allow a direct electrical connection between conductive layers 400 & 460.

(48) In one embodiment, the reducer solvent component is 50-70% n-butyl acetate and 30-50% xylene.

(49) In one embodiment, the reducer solvent component is 50-70% methyl acetate and 30-50% xylene.

(50) In one embodiment, combined intermediate layer 441 comprises 60%-65% by weight of the reducer solvent component.

(51) In one embodiment, combined intermediate layer 441 comprises 15-20% by weight of the reducer solvent component.

(52) In one embodiment, the reducer solvent component of combined intermediate layer 441 comprises an acrylic.

(53) In one embodiment, the reducer solvent component of combined intermediate layer 441 comprises a polyurethane binder.

(54) In one embodiment, combined intermediate layer 441 comprises 15%-25% by weight of an electroluminescent pigment component.

(55) In one embodiment, combined intermediate layer 441 comprises 15%-20% by weight of a high-dielectric pigment component.

(56) In one embodiment, combined intermediate layer 441 has a thickness of substantially 0.002″.

(57) In one embodiment, the various layers are applied by High Pressure Low Volume spray techniques, wherein each coating is atomized by compressed air and deposited on the conformal substrate in this manner, and the coating then flows after deposition to the proper film thickness.

(58) In one embodiment, the various layers are applied by aerosol spray techniques, wherein each coating is atomized by a propellant inside of a can, and deposited on the conformal substrate in this manner, and the coating then flows after deposition to the proper film thickness.

(59) In one embodiment, the propellant inside of the can comprises propane.

(60) In one embodiment, the various layers are applied by electrostatic spray techniques, where each coating is atomized by compressed air and deposited on the charged surface of the conformal substrate in this manner, and the coating then flows after deposition to the proper film thickness.

(61) Those of skill in the art will appreciate that known techniques of applying spray coatings may not always result in a completely consistent coating in terms of pigmentation, color, or transparency, and that consequently, a “transparent” layer may not be completely transparent, or may be at least partially transparent.