Electro-optic displays, and materials and methods for production thereof
09554495 ยท 2017-01-24
Assignee
Inventors
- Guy M. Danner (Somerville, MA, US)
- Valerie C. Northrop (Waltham, MA, US)
- Jonathan D. Albert (Philadelphia, PA, US)
- Holly G. Gates (Somerville, MA, US)
- Erik van Veenendaal (Eindhoven, NL)
- Fredericus J. Touwslager (Veidhoven, NL)
Cpc classification
Y10T156/1062
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B37/02
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/1052
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T29/49124
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B38/10
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/1057
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/109
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H05K13/00
ELECTRICITY
B32B2457/202
PERFORMING OPERATIONS; TRANSPORTING
International classification
B32B37/02
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B32B38/04
PERFORMING OPERATIONS; TRANSPORTING
B32B38/10
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An electro-optic display is produced using a sub-assembly comprising a front sheet, an electro-optic medium; and an adhesive layer. An aperture is formed through the adhesive layer where the adhesive layer is not covered by the electro-optic medium, and the sub-assembly is adhered to a backplane having a co-operating member with the aperture engaged with a co-operating member, thus locating the sub-assembly relative to the backplane. In another form of electro-optic display, a chip extends through an aperture in the electro-optic medium and adhesive layer. In a third form, the aforementioned sub-assembly is secured to a backplane and then a cut is made through both backplane and sub-assembly to provide an aligned edge.
Claims
1. A process for the production of an electro-optic display, the process comprising: forming a sub-assembly comprising in order, a front sheet; a layer of electro-optic medium; and an adhesive layer, the front sheet comprising a light-transmissive electrically-conductive layer and at least one additional layer on the opposed side of the electrically-conductive layer from the layer of electro-optic medium, the additional layer serving to support the electrically-conductive layer and to protect it against mechanical damage, the additional layer being larger than the layer of electro-optic medium; securing the sub-assembly to a backplane comprising at least one pixel electrode and larger than the layer of electro-optic medium, only a peripheral portion of the additional layer being secured to a peripheral portion of the backplane, thereby forming a seal around the layer of electro-optic medium; and cutting through only the peripheral portions of the additional layer and the backplane, thereby removing edge portions of both the additional layer and the backplane, and leaving the edge of the additional layer aligned with the edge of the backplane.
2. A process according to claim 1 wherein the electro-optic medium comprises a rotating bichromal member or electrochromic material.
3. A process according to claim 1 wherein the electro-optic medium comprises an electrophoretic material comprising a plurality of electrically charged particles disposed in a fluid and capable of moving through the fluid under the influence of an electric field.
4. A process according to claim 3 wherein the electrically charged particles and the fluid are confined within a plurality of capsules or microcells.
5. A process according to claim 3 wherein the electrically charged particles and the fluid are present as a plurality of discrete droplets surrounded by a continuous phase comprising a polymeric material.
6. A process according to claim 3 wherein the fluid is gaseous.
7. A process according to claim 1 wherein the cutting step also effects at least one of: (a) removal of at least one contact tab from the sub-assembly; (b) removal of at least one tacking strip from the sub-assembly; and (c) formation of at least one aperture through the display.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are not strictly to scale. In particular, for ease of illustration, the thicknesses of the various layers are greatly exaggerated relative to their lateral dimensions. The present invention is well adapted for the production of thin, flexible electro-optic displays; typically, the sub-assemblies used in the processes described below will have thicknesses of about 100 m, and can be laminated to flexible backplanes of similar thickness.
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DETAILED DESCRIPTION
(9) As will be apparent from the foregoing Summary of the Invention, the present invention has a number of different aspects. However, as illustrated in the preferred embodiments discussed below, a single physical electro-optic display or process for the production thereof may make use of multiple aspects of the present invention. For example, the process described below with reference to
(10) Before describing in detail various embodiments of the present invention it is useful to set out certain definitions. The term backplane is used herein consistent with its conventional meaning in the art of electro-optic displays and in the aforementioned patents and published applications, to mean a rigid or flexible material provided with one or more electrodes. The backplane may also be provided with electronics for addressing the display, or such electronics may be provided in a unit separate from the backplane. In flexible displays (and the present invention is especially although not exclusively intended for use in flexible displays), it is highly desirable that the backplane provide sufficient barrier properties to prevent ingress of moisture and other contaminants through the non-viewing side of the display. If one or more additional layers need to be added to the backplane to reduce ingress of moisture and other contaminants, the barrier layers should be located as closely as possible to the electro-optic layer so that little or no edge profile of low barrier materials is present between the front (discussed below) and rear barrier layers.
(11) As already indicated, the sub-assembly used in the present processes may comprise at least one electrode layer, most commonly a single continuous front electrode extending across the entire display. Typically, the surface of the sub-assembly which remains exposed after lamination to the backplane will form the viewing surface through which an observer views the display. As with the backplane, the sub-assembly may provide barrier properties to prevent ingress of moisture and other contaminants through the viewing side of the display. If one or more additional layers need to be added to the sub-assembly to reduce ingress of moisture and other contaminants, the barrier layers should be located as closely as possible to the electro-optic layer so that little or no edge profile of low barrier materials is present between the front and rear barrier layers.
(12) Reference will be made hereinafter to loose and tight release sheets. These terms are used in their conventional meaning in the art to indicate the magnitude of the force necessary to peel the relevant release sheet from the layer with which it is in contact, a tight release sheet requiring more force than a loose release sheet. In particular, if a stack of layers has a tight release sheet on one side and a loose release sheet on the other, it is possible to peel the loose release sheet away from the stack without separating the tight release sheet from the stack.
(13) Some of the displays and sub-assemblies used in the present invention contain two separate adhesive layers. When necessary or desirable, the two adhesive layers will be denoted as front and rear adhesive layers, these terms denoting the position of the relevant adhesive layer in the final display; the front adhesive layer is the adhesive layer lying between the electro-optic medium and the viewing surface of the display, while the rear adhesive layer lies on the opposed side of the electro-optic layer from the front adhesive layer. In the common situation where a display has a single front electrode between the electro-optic layer and the viewing surface and a plurality of pixel electrodes on the opposed side of the electro-optic layer, the front adhesive layer lies between the electro-optic layer and the front electrode, while the rear adhesive layer lies between the electro-optic layer and the pixel electrodes.
(14) A preferred process which makes use of both the ALLA and CSSA aspects of the present invention will now be described with reference to
(15)
(16) In the second step of the process, the structure shown in
(17) The stages of the process described thus far will typically be carried out either on continuous webs of material, or on large sheets of material sufficient to form several final displays. For ease of illustration,
(18) In the next step, the remaining portions 208 of the loose release sheet are peeled from the structure shown in
(19) The front substrate is designed to provide the front light-transmissive electrode for the final display. The front substrate 120 can also provide the necessary mechanical support for this thin and relatively fragile front electrode. In addition, the front substrate preferably provides all necessary water vapor and oxygen barriers, and ultra-violet absorption properties, desirable to protect certain electro-optic layers, especially electrophoretic layers. The front substrate may also provide desirable anti-glare properties to the viewing surface of the final display. The front substrate 120 serves all of these functions while still being thin and flexible enough to enable the formation of a final display sufficiently flexible to be wound around a mandrel of (say) 15 mm diameter. As already noted, the front substrate includes a masking film; this masking film is provided primarily to increase the thickness of the front substrate so as to facilitate handling of this substrate during laminations. In a preferred process, the total thickness of the front substrate as it remains in the final display (i.e., with the masking film removed) is only about 1 mil (25 m) and the masking film is used to add about 2 mil (51 m) to this thickness for ease of handling. The masking film also typically serves to prevent scratching or adhesion of dust or debris to an adjacent anti-glare layer during the laminations. The structure resulting from this step of the process is shown in
(20) The steps of the process described so far as essentially identical to those of the process described with reference to FIGS. 2A to 2E of the aforementioned 2008/0057252, to which the reader is referred for further information.
(21) At this point, a second, thin adhesive layer 122 is coated on to a third release sheet 124, and apertures 126 are formed though both the adhesive layer 122 and the release sheet 124 at positions corresponding to where top plane connections (connections between the backplanes and the front electrodes) will be present in the final displays. At the same time, the release sheet is cut, preferably discontinuously, along a line 127 (see
(22) The next stage of the process is singulation, that is to say separation of the portions of the sub-assembly corresponding to individual displays. The result of this singulation step is illustrated in
(23) (a) cutting of the sheet or web into pieces of the size required for individual displays;
(24) (b) formation of apertures through the adhesive layer 122, the front substrate 120 and the release sheet 124 required for mechanical alignment of the sub-assembly during subsequent lamination to a backplane; and
(25) (c) formation of an aperture through the front substrate 120, and the adhesive layer 122, this aperture being ultimately used to mount an electronic circuit device on the backplane of the final display.
(26) As illustrated in
(27) Operation (b) is effected by providing two small circular apertures 128 adjacent one edge (the lower edge as illustrated in
(28) Operation (c) is effected by providing a rectangular aperture 130 in the tail portion of the FPL, this rectangular aperture 130 extending completely through the FPL, i.e., through the front substrate 120, the adhesive layer 122 and the release sheet 124. As discussed below with reference to the ST process of the present invention, the type of FPL shown in
(29) As also illustrated in
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(32) Detailed consideration will now be given to the simultaneous trimming (ST) process of the present invention. As noted above, when laminating front plane laminates to a backplane, the FPL must typically be aligned with respect to backplane features, for example contact pads designed to provide contacts to the electrode layer present in the front plane laminate. Depending on the design requirements, the FPL can be designed to be smaller than the backplane (to allow access to electrical connections on areas of the backplane not covered by the FPL) or the same size as the backplane. If the FPL, or a barrier layer laminated over the FPL, is the same size as the backplane, achieving a clean edge alignment can be difficult in practice, since there is always some tendency for the FPL not to line up exactly with the backplane. Also, certain features desirable during manufacture, such as inspection tabs or tacking strips, can be undesirable if present in the finished display module.
(33) There is an increasing tendency to use electro-optic media with thin backplanes based on polymeric films (for example, poly(ethylene terephthalate) or poly(ethylene naphthalate), PEN, available commercially under the Registered Trade Mark TEONEX from DuPont Teijin Films of Hopewell Va.) or metal foils. Electro-optic displays based on such thin backplanes can be flexible or rollable and hence usable in certain applications (for example, a large display screen capable of being stored in a cellular telephonesee the aforementioned 2002/0090980) where traditional displays cannot be used. It has now been found that, using the simultaneous trimming process of the present invention, an FPL laminated to such a polymeric or metal foil backplane can readily be cut by industrial methods, for example laser cutting or die cutting, and that such cutting of an FPL/backplane laminate enables an accurately matched edge to be achieved between the FPL (or a barrier layer overlying the FPL) and the backplane, without adverse effects on the functionality of the final display. Such cutting also allows for the removal of features useful during manufacture but not wanted in the final display.
(34) A preferred simultaneous trimming process of the present invention will now be described with reference to
(35) The FPL shown in
(36) In the simultaneous trimming process shown in
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(38) It will be seen from
(39) The ST process shown in
(40) It will be apparent to those skilled in the technology of electro-optic displays that numerous changes and modifications can be made in the preferred embodiments of the present invention already described without departing from the scope of the invention. For example, in the preferred processes of the invention illustrated in the drawings, the inverted front plane laminate is cut into pieces of the size required for an individual display (see
(41) Furthermore, although the invention has been shown in
(42) Numerous other variations of the processes of the present invention will readily be apparent to those skilled in the technology of electro-optic displays. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not in a limitative sense.