CN101836167A - 用在电光显示器中的多层板 - Google Patents
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Abstract
一种在电光显示器中用作前子组件的多层膜(100),顺序地包括:透光导电层(114);透光第一保护层(112);透光湿气阻隔层(108);以及透光第二保护层(106)。该多层膜可以用在通过美国专利No.6,982,179或专利公开No.2007/0109219所描述的工艺形成的电光显示器中。
Description
本申请涉及(a)美国专利No.6,982,178;(b)美国专利No.7,236,292;(c)美国专利公开No.2004/0155857;(d)美国专利No.7,110,164;(e)美国专利公开No.2007/0109219;(f)美国专利公开No.2007/0152956;(g)美国专利公开No.2007/0211331;(h)在2007年9月6日提交的序号为11/850,831的美国申请;以及(i)在2007年12月6日提交的序号为11/951,489的美国申请。
为了方便,在下文中将以上申请和专利称为“电光显示器制造”或“EODM”专利和申请。
关于电光显示器领域的背景术语及状况在美国专利No.7,012,600中讨论,读者可以参考该专利以得到进一步信息。相应地,以下将对该领域的背景术语及状况作简短概述。
本发明涉及用在电光显示器中的多层板。这样的电光显示器一般地包含固态的电光媒质(为了方便在下文中将这样的显示器称为“固态电光显示器”),该固态是指在该电光媒介具有固态外表面的意义下的固态,尽管该媒质可以并且通常具有内部液体或气体填充的空间。因此,术语“固态电光显示器”包括封装的电泳显示器、封装的液晶显示器以及以下所讨论的其它类型的显示器。
作为应用到材料或显示器的术语“电光”,其在此使用的是在成像技术领域中的常规含义,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种光学性质不同,通过向该材料施加电场使该材料从第一显示状态转变到第二显示状态。
在这里以本领域中的常规含义使用术语“双稳”和“双稳定性”以指示包括具有第一和第二显示状态的显示部件的显示器,所述第一和第二显示状态至少有一种光学性质不同,并且使得任何给定部件通过具有有限持续时间的寻址脉冲被驱动成呈现其第一或第二显示状态后,在寻址脉冲终止后,该状态将持续至少是改变该显示部件的状态所需寻址脉冲的最小持续时间的几倍时间,例如至少是四倍时间。
已知几种类型的电光显示器,例如:(a)旋转双色元件(rotating bichromal member)显示器(参见例如美国专利No.5,808,783;5,777,782;5,760,761;6,054,0716,055,091;6,097,531;6,128,124;6,137,467和6,147,791);(b)电致变色显示器(参见例如O′Regan,B.等人,Nature 1991,353,737;Wood,D.,Information Display,18(3),24(2002年3月);Bach,U.等人,Adv.Mater.,2002,14(11),845;和美国专利No.6,301,038;6,870.657和6,950,220);(c)电湿润显示器(参见Hayes,R.A.等人的“基于电湿润技术的视频速度电子纸”(″Video-Speed Electronic Paper Based on Electro wetting″),Nature,425,383-385(2003年9月25日)和美国专利公开No.2005/0151709);(d)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穿过流体。(参见美国专利No.5,930,026;5,961,804;6,017,584;6,067,185;6,118,426;6,120,588;6,120,839;6,124,851;6,130,773和6,130,774;美国专利申请No.2002/0060321;2002/0090980;2003/0011560;2003/0102858;2003/0151702;2003/0222315;2004/0014265;2004/0075634;2004/0094422;2004/0105036;2005/0062714和2005/0270261;以及国际申请公开No.WO00/38000;WO00/36560;WO 00/67110和WO 01/07961;以及欧洲专利No.1,099,207 B1;和1,145,072 B1;以及在前述的美国专利No.7,012,600中论述的其它麻省理工学院(MIT)和伊英克(E Ink)公司的专利和申请)
存在几种电泳媒质的不同变形。电泳媒质可以使用液体或气态流体;对于气态流体参见例如Kitamura,T.等人的“在电子纸类显示器中电子色粉的运动”(″Electrical toner movement for electronic paper-like display″),IDWJapan,2001,Paper HCSl-I和Yamaguchi,Y.等人的“利用带静电的绝缘粒子的色粉显示器”(″Toner display using insulative particles chargedtriboelectrically″),IDW Japan,2001,Paper AMD4-4);美国专利公开No.2005/0001810;欧洲专利申请1,462,847;1,482,354;1,484,635;1,500,971;1,501,194;1,536,271;1,542,067;1,577,702;1,577,703和1,598,694;以及国际申请WO 2004/090626;WO 2004/079442和WO 2004/001498。该媒质可以为封装的,包括大量小囊,其中每一个小囊本身包含内相以及环绕内相的囊壁,其中所述内相含有悬浮在液体悬浮媒质中的可电泳运动的粒子。一般地,这些囊本身保持在聚合粘合剂中以形成位于两个电极之间的粘附层;参见前述的MIT和E Ink的专利及申请。可替代地,在封装的电泳媒质中的围绕分离微囊的壁可以用连续的相代替,因而产生所谓的聚合物分散的(polymer-dispersed)电泳显示器,其中电泳媒质包括多个电泳流体的分离的小滴以及聚合物材料的连续相;参见例如美国专利No.6,866,760。为了本申请的目的,这样的聚合物分散的电泳媒质被认为是封装的电泳媒质的子类。另一种变形是所谓的“微单元电泳显示器”,其中带电粒子和流体保持在形成于载体媒质(通常是聚合物膜)内的多个腔内,参见例如美国专利No.6,672,921以及6,788,449。
电泳媒质可以在“快门模式(shutter mode)”下工作,该快门模式下一种显示状态基本上是不透明而一种显示状态是透光的。参见例如美国专利No.6,130,774和6,172,798,以及美国专利No.5,872,552、6,144,361、6,271,823、6,225,971和6,184,856。介电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。其它类型的电光显示器也能在快门模式下工作。
诸如封装的液晶媒质的其它类型的电光显示器也可以用在本发明中。
电光显示器通常包括电光材料层和设置在该电光材料的相对的侧上的至少两个其它层,这两层中的其一为电极层。在大多数这种显示器中两层均为电极层,且将这两个电极层或其一图案化,以便限定出显示器的像素。例如,将一个电极层图案化为细长的行电极,将另一个电极层图案化为沿与行电极呈直角延伸的细长的列电极,则像素通过行与列电极的交叉点来限定。可替代地,并且更为常见地,一个电极层具有单个连续电极的形式,而另一个电极层被图案化为像素电极的矩阵,每一个像素电极限定出显示器的一个像素。在另一种旨在与触针、打印头或类似的分离于显示器的可移动电极一起使用的电光显示器中,只有邻近该电光层的多个层中的一层包括电极,在电光层的相对侧上的层一般地作为保护层旨在防止可移动电极损害电光层。
三层的电光显示器的制造通常包括至少一个层压操作。如前述的美国专利No.6,982,178中所讨论的,许多用在固态电光显示器中的部件以及用于制造这种显示器的方法均来源于在液晶显示器(LCD)中所使用的技术,尽管液晶显示器采用的是液体而不是固态媒质,但显然其还是电光显示器。然而用于组装LCD的方法不能用于固态电光显示器。通常,组装LCD需要通过以下的过程:在分开的玻璃基底上形成背板和前电极,然后将这些部件粘附地固定在一起并在它们之间留有小开口,而后将得到的组件置于真空下,并将该组件浸入到液晶的浴中,从而使液晶流经背板和前电极之间的开口。最后,随着液晶流到适当位置将开口密封,从而获得最终的显示器。
不能简单地将这种LCD组装工艺转用到固态电光显示器。因为电光材料是固态的,在将背板和前电极这两个整体相互固定之前其一定是存在于背板和电极之间。此外,液晶材料在无需附着于前电极或背板的条件下可被简单地置于这二者之间,与液晶材料相比,固态电光媒质则通常均需要被固定在前电极和背板上。在一些情况下固态电光媒质在前电极上形成,这是因为这通常比在包含电路的背板上形成媒质更加容易实现,然后将前电极/电光媒质的组合压到背板上,通常这种层压是通过在电光媒质的整个表面覆盖粘附剂,然后在一定的温度、压力以及可能为真空的条件下进行层压。
用于电泳显示器的最终层压的大多数现有技术的方法基本上为成批的方法,其中恰好在最终的组装之前组合电光媒质、层压粘附剂以及背板在一起,因此,期望提供更适合于大量生产的方法。
前述的美国专利No.6,982,178描述了一种组装固态电光显示器(包括封装的电泳显示器)的方法,该方法能较好地适用于大量生产。该专利实质上描述了所谓的“前平面层压(FPL)”,该“前平面层压”顺序地包括透光导电层、与导电层电接触的固态电光媒质的层、粘附层、以及释放板。一般地,该透光导电层由透光基底所承载,所述透光基底优选地为柔性的,这种柔性的含义是该基底能够被手动地卷绕(比方说)直径为10英寸(254毫米)的柱状物而不会永久变形。本专利及此处所使用的术语“透光”表示所指定的层能够使足够的光通过,以使观察者能够看穿该层以观察到电光媒质的显示状态上的变化,而通常这种变化是通过导电层和相邻的基底(如果有的话)所观看到的。在电光媒质显示处于非可见的波长的反射率的变化的情况下,术语“透光”当然应该被解释为是指相关的非可见的波长的透过。一般地,基底为聚合物膜,并且通常其厚度在约1至约25密尔(25至634μm)范围内,优选地约2至约10密尔(51至254μm)。适合地,导电层可以为诸如铝或ITO的薄的金属或金属氧化物层,或者可以为导电聚合物。涂覆有铝或ITO的聚对苯二甲酸乙二酯(PET)膜是商业可得的,例如来自特拉华州威尔明顿的杜邦公司(E.I.du Pont de Nemours & Company,Wilmington DE)的“铝化Mylar”(″Mylar″为注册商标),在前平面层压中可以使用这种商业材料并具有良好的效果。
前述的2004/0155857描述了所谓的“双释放膜”,该“双释放膜”实质上为前述的美国专利No.6,982,178的前平面层压的简化版。其中一种双释放板的形式包括了夹在两个粘附层之间的固态电光媒质层、一个或两个由释放板所覆盖的粘附层。双释放层的另一种形式包括夹在两个释放板之间的固态电光媒质层。这两种形式的双释放膜均旨在用于与已经描述的用于从前平面层压组装电光显示器的工艺基本上类似的工艺中,但其包括两个分离的层压。通常,在第一次层压中是将双释放板层压到前电极以形成前子组件,然后在第二次层压中将前子组件层压到背板以形成最终的显示器,但是如果需要的话,这两次层压的顺序可以反过来。
利用前述的前平面层压或双释放膜而制造的电光显示器在电光层本身和背板之间具有一层层压粘附剂,并且该层压粘附层的存在会影响显示器的电光特性。具体地说,层压粘附层的电导率会影响到显示器的低温性能和清晰度。显示器的低温性能(据经验发现)可以通过增大层压粘附层的电导率而得到提高,例如,如前述的美国专利7,012,735和7,173,752所描述的,通过采用四丁基六氟磷酸胺或其它材料来对该层掺杂。然而,以这种方式增大层压粘附层的电导率趋向于增加像素晕染(pixel blooming)(这是一种现象,指的是响应于像素电极处的电压变化而改变光学状态的电光层的面积大于像素电极本身的面积),并且该晕染趋向于降低显示的清晰度。所以,该类型的显示器显然实质上需要在低温性能和显示清晰度之间折衷,而实际上通常会牺牲低温性能。
前述的2007/0109219描述了所谓的“倒置的前平面层压”,其为在前述的美国专利No.6,982,178中所述的前平面层压的变形。该倒置的前平面层压顺序地包括:透光保护层和透光导电层中的至少一个、粘附层、固态电光媒质层以及释放板。该倒置的前平面层压是用于形成在电光层和前电极或前基底之间具有层压粘附层的电光显示器;在电光层和背板之间可以有或可以没有通常很薄的第二粘附层。这种电光显示器兼具较好清晰度和低温性能。
某些电光显示器的新兴市场需要显示器为薄的、柔性的且可卷起的,以便该显示器可以在围绕心轴(其仅具有几毫米的直径)环绕的储存位置和工作位置之间重复性地移动,其中该显示器形成相对大型平板的显示屏。例如,已经建议(参见前述的2006/0194619)了提供一种具有该类型的柔性显示器的移动电话,以便于由电话接收的E-mail信息的读取。为了提供最有利于用于该目的的显示器的尺寸,需要这种柔性显示器的厚度不大于约0.2mm。
提供这样的薄显示器的一个主要挑战是将电光媒质相对于包括辐射的环境密封。如前述的E Ink的一些专利和申请所讨论的,一些电光媒质对氧和湿气敏感,因此利用这种媒质的显示器包含阻隔层以防止氧和湿气扩散进入电光媒质(以及湿气的情况下,扩散出电光媒质)是必要的。还期望提供防止紫外线辐射到达电光层的阻隔。为了提供具有商业上可接受的外观以及可抵抗机械损伤的显示器,显示器的观看表面至少在一些情况下应该具有防眩光的硬涂层。最后,在该显示器结构的介于电光媒质和观看表面之间的部分(下文中,为了方便称为显示器的“前子组件”)需要提供形成显示器的前电极的导电层。
在足够薄的前子组件中提供以用在高度柔性显示器中的所有这些功能是相当困难的事情。尽管理论上期望在单独的、单片层中提供所有需要的功能,然而似乎不存在能够提供所有这些功能于单独层中的已知材料,况且,尽管这样的材料可能被开发,但对于用在高度柔性显示器中其可能是无法想象的昂贵。因此,需要使用多层前子组件。
然而,使用这样的多层前子组件加剧了生产高度柔性显示器中的另一个问题,即由于这种基底缺乏硬度在非常薄的基底上执行包括涂覆、处理、层压以及组装操作的制造操作的困难。可以通过尽量采用网处理(webprocessing)使这些困难降低到一定程度,但是高度柔性显示器的最终组装需要包括前子组件、电光媒质以及(一般地)层压粘附层的薄的子组件至薄背板的层压,且该层压通常不能采用网处理来执行。
在设计高度柔性显示器中的另一个问题是“蠕变”现象。通常期望将柔性显示器储存在卷起的或卷绕的构造中(例如该显示器可以被储存为卷绕柱状心轴或围绕移动电话或类似的电子设备的外部折叠)。当该柔性显示器要使用时,其从卷起展开或从卷绕展开以处于基本上平面的构造,随后在使用后再卷起或再卷绕。除非该柔性显示器被谨慎地设计,这种柔性显示器的重复的从卷起展开或从卷绕展开很可能引起正常存在的前基底和后基底相对于彼此略微地移动(蠕变)。这种蠕变是非常不期望的,因为它可能导致显示器的不同层相互之间的分层,或在显示器的不同部分之间的电光性能上引入差异。在使用彩色滤光片的彩色显示器中蠕变是特有的问题,这是因为在相邻于显示器的观看表面布置的彩色滤光片和靠近显示器的后表面存在的像素电极之间的任何移动破坏在彩色滤光元件和像素电极之间的需要用于精确的色彩再现的对准,且因此不利地影响到由显示器产生的色彩。
至今,电光显示器的前电极一般地由溅射的金属氧化物陶瓷形成,例如铟锡氧化物(ITO)。这种溅射的陶瓷层昂贵且构成显示器整个成本的重要部分。相应地,期望使用能够降低成本的连续的或湿式涂覆的传导层来替代溅射的陶瓷层,但其也可能降低前子组件的阻隔性能,这是因为ITO本身提供一些有用的阻隔性能。本发明的优选的实施例便于这种连续的或湿式涂覆的传导层的使用且仍保持不错的阻隔性能。
本发明寻求提供在薄的可卷起的电光显示器中用作前子组件的多层板,该板能够减少或消除至少一些前述的问题。
本发明提供一种用于在电光显示器中用作前子组件的薄且可卷起的多层板。本发明还提供用于以允许每一个单个层独立于其它层被优化以实现其功能的方式形成该多层板的层压工艺。还可以针对其特殊功能经济节约地制造这些层。
相应地,本发明提供一种在电光显示器中用作前子组件的多层膜,该多层膜顺序地包括:透光导电层;透光第一保护层;透光湿气阻隔层;以及透光第二保护层。
可以将这种多层膜制作得非常薄;一般地,本发明的多层膜具有不超过约100μm的总厚度,并且期望地不超过约50μm;计算该总厚度时不包括在将该膜合并到功能电光显示器中之前移除的任何层。例如,如以下更详细描述的,通常期望提供具有可移除的掩蔽板的膜以便于处理在制造多层膜期间所涉及的薄板,该掩膜一般地在将膜合并到最终电光显示器之前被移除,并且当计算本发明的多层膜的总厚度时省略这种的掩膜的厚度。
在本多层膜中,透光导电层包括铟锡氧化物或湿式涂覆的传导层。其它透光导电层当然可以被使用,例如非常薄的诸如铝的金属的溅射层。由于通常期望保护存在于最终显示器中的电光媒质以避免大量曝光于紫外线辐射,第一和第二保护层的至少一个包括紫外线吸收剂。湿气阻隔层可以包括氧化铝。膜可以包括在第二保护层的与透光导电层相对的侧上的防眩光硬涂层。可替代地或附加地,膜进一步包括第二保护层的与透光导电层相对的侧上的掩膜,该掩膜可从与其相接触的层移除而基本上不损伤所述层;显然,如果存在防眩光硬涂层和掩膜二者,掩膜超出硬涂层之外。本发明的膜可以进一步包括布置在第一保护层和湿气阻隔层之间的粘附层。在一些形式的多层膜中,为了提供附加的湿气阻隔保护,湿气阻隔层包括通过非阻隔中间层分离的第一和第二湿气阻隔子层。该中间层可以为粘附层。
本发明还提供一种使用本发明的多层膜的用于组装电光显示器的工艺。这种组装工艺可以采用几种不同的方式来完成。例如,通过下述将多层膜以前述的美国专利No.6,982,178所描述的方式转变为前平面层压:直接涂覆电光层至多层膜的透光导电层上,单独地涂覆粘附层至释放板上,且随后通过将粘附层与电光层接触以将两个得到的子组件层压(一般地在热和压力的条件下)在一起以形成前平面层压。随后从前平面层压剥离释放板并层压剩下的层至背板以形成最终显示器。
然而,通常优选地是采用通过如前述的2007/0109219中所描述的倒置的前平面层压来将多层膜转至电光显示器。相应地,本发明提供一种用于组装电光显示器的工艺,包括:提供多层膜,其本身顺序地包括:透光导电层;透光第一保护层;透光湿气阻隔层;以及透光第二保护层;提供包括夹在第一和第二粘附层之间的电光媒质层的双释放膜;提供包括至少一个像素电极的背板,利用与导电层接触的第一粘附层层压双释放膜至多层膜,从而固定该双释放膜至多层膜;以及利用与背板接触的第二粘附层层压双释放膜至背板,从而固定该双释放膜至背板;在该工艺中,两个层压可以按二者中任一的顺序完成。
在本发明的工艺中,多层膜进一步包括在第二保护层的与透光导电层相对的侧上的掩膜,该掩膜从与其相接触的层可移除而基本上不损伤该层,在多层膜被固定至双释放膜之后可从该层移除该掩膜。在该工艺中,多层膜一般地具有不超过约50μm的总厚度,不包括在将该膜合并到功能电光显示器中之前移除的任何层,并且层压的多层膜、 双释放膜和背板的总厚度一般地不超过大约150μm。
本发明还提供用于形成本发明的优选的多层膜的两种工艺。这两种工艺中的第一种包括:提供第一聚合物板,其包括紫外线吸收剂并在其一个表面上具有透光导电层;提供在其一个表面上具有湿气阻隔层的第二聚合物板;涂覆粘附层至第二聚合物板的涂覆有湿气阻隔层的表面上或者没有承载导电层的第一聚合物板的表面上;以及使所述第一和第二聚合物板接触在一起,使导电层暴露且粘附层和湿气阻隔层布置在这两个聚合物板之间。该工艺进一步包括提供在第二聚合物板的远离于湿气阻隔层的表面上的防眩光硬涂层。
这两种工艺中的第二种包括:提供各自包括聚合物层的第一和第二聚合物板,该聚合物层的一个表面上具有湿气阻隔层;在一个湿气阻隔层上涂覆粘附层;使第一和第二聚合物板接触在一起,其中粘附层和两个湿气阻隔层布置在这两个聚合物层之间;引入紫外线吸收剂到一个聚合物层中;以及在一个聚合物层的暴露的表面上形成传导层。该第二种工艺进一步包括提供在远离于导电层的聚合物层的表面上的防眩光硬涂层。
附图说明
图1是通过本发明的第一多层板的横截面示意图;
图2是通过本发明的第二多层板的横截面示意图。
具体实施方式
附图不是严格地依照比例。特别地,为了便于示意,不同层的厚度相对于其侧向尺寸显著夸大。本发明很适合于薄的柔性电光显示器的生产;一般地,以下所描述的多层板的厚度(在没有掩膜的情况下测量的,其中在使用最终的显示器之前掩膜已被丢弃)不超过约100μm,且可能不超过约25μm,并且该板可以被层压至类似厚度的柔性背板。已经发现当与电光媒质和背板一起使用时,本发明的薄的多层板可以有效地减少蠕变。
附图的图1是通过本发明的第一多层板(总体标示为100)的横截面示意图。该板100包括厚度约2密尔(51μm)的掩膜102、以及与该掩膜102接触的防眩光硬涂层104。在使用最终显示器之前移除的和可能在板100被层压至柔性背板(未示出)以形成最终显示器之前移除的掩膜102,其用于在制造板100期间保护该硬涂层104免受损伤。掩膜102还用于增加板100的厚度及硬度,从而便于对其进行处理。
板100还包括0.5密尔(13μm)的聚对二苯甲酸乙二酯(PET)层106,其在其远离硬涂层104的表面上承载氧化铝(AlOx)阻隔层108。该阻隔层108与薄的(约5μm)固化的粘附层110相接触,该粘附层110将阻隔层108固定至第二0.5密尔(13μm)的PET层112。不同于PET层106,PET112包含紫外线吸收剂。最后,板100包括ITO层114,其用作为阻隔层并还形成最终显示器的前电极。相应地,ITO层114在板100的一个外表面上,以便其尽可能地接近电光媒质。相反,板100的结构将AlOx层108置于堆叠层的中间,介于两个PET层106和112之间。该薄的AlOx层108的这种布置减少了对该阻隔层机械损伤的机会。
用于制造图1中示出的板100的优选的工艺如下。把紫外线吸收剂合并到PET板112中并且ITO层114被溅射到所得到的UV吸收PET层的一个表面上。单独地,AlOx被溅射到第二PET板106上。可固化的湿粘附剂110被涂覆到第二PET板106的涂覆AlOx的表面上或者第一PET板112的无涂覆ITO的表面上,且这两个PET板被固定在一起以形成图1中的包括层106至114的子组件。最后,防眩光硬涂层104被涂覆到PET层106的暴露的表面上,并且将掩膜102(其一般地以成卷的形式作为预形成的膜被提供)应用到硬涂层104的暴露的表面以增加板100的处理厚度并保护硬涂层104。
板100的总厚度(在没有可移除的掩膜102的情况下)小于50μm。如已指出的,两个PET层106和112的每一个为0.5密尔厚,这样它们的总厚度为1密尔或25μm。粘附层110约5μm厚。防眩光硬涂层105典型地具有2μm或更小的厚度。溅射的阻隔层108和ITO层114的每一个的厚度为约1μm的量级。相应地,板100的总厚度约为34μm。在常规的卷至卷操作期间操作该厚度的板具有相当大的困难,并因此期望典型地具有约50μm的厚度的相对厚的掩板102以提供具有一个厚度的板,降低在常规的网处理装置上的涂覆难度。
在该厚度的单个板中提供所有需要的阻隔、紫外线保护和硬涂层(机械保护和防眩光)功能的能力能够生产比现有技术的设计中一般地可能的薄得多的电光显示器,其中板100的不同功能通过分离层来提供。如已说明的,板100可以具有约34μm的厚度。一般地双释放膜包括夹在25μm的粘附层(其被层压到板100)和6μm的粘附层(其被层压到背板)之间的25μm的电泳层,总厚度约为56μm(不包括在将双释放膜合并到最终显示器之前势必移除的释放膜)。通过在聚合物膜上印刷有机半导体,制造出总厚度(即使包括了任何所需的附加阻隔层)不大于约25μm的背板是可能的。由板100生产的电光显示器以及这种双释放膜和背板的总厚度约为115μm,且物理特性和商业的5密尔(127μm)的PET膜没有很大不同。因此,这种显示器可以容易地绕(比方说)直径为10mm的心轴卷绕,或卷绕类似厚度的移动电话或类似的电子设备。
图1所示的结构可能具有许多变化。如果需要可以省略掩膜102。在一些应用中还可能省略硬涂层104,留下PET层106的一个表面作为板100的观看表面。根据用于紫外线辐射的特定的电光媒质的敏感性,以及显示器可能的预期的使用(例如打算在室内演讲剧场用作显示屏的可卷起显示器可能不需要紫外线保护),可以从PET层112中省略紫外线吸收剂,或以其它方式提供紫外线吸收,如前述的2007/0109219中所描述的。AlOx阻隔层可以由具有足够透明度和阻隔性能的任何溅射的或蒸发的金属或陶瓷层或聚合物来替代;适合的材料的例子包括ITO、铝、氧化硅、碳化硅以及在注册贸易商标CLARIS,ACLAR和SARAN下市售的均聚物。类似地,ITO层114可以由具有足够透明度和传导性的任何溅射的或蒸发的金属或陶瓷层或聚合物来替代;适合的材料的例子包括铝、诸如PEDOT(聚(3,4-乙烯基二氧噻吩)的传导性聚合物以及碳纳米管。
AlOx层108和ITO层114的组合提供比单独使用二者中任一层更有效的阻隔层。该溅射的膜的阻隔性能被不可避免地存在于溅射的层中的针孔所限制。如在制造以上描述的板100中所实施的,通过将两个溅射的膜层压在一起,形成冗余的阻隔层,其中在该两个阻隔层中随机分布的针孔的重叠是非常不可能地。
板100也是机械上耐用的。机械压力趋向于引起AlOx和ITO阻隔层中的断裂,但冗余的阻隔层的存在以及将这些阻隔层应用于通过薄的粘附层分离的不同聚合物(PET)膜的事实趋向于消除这种在两个阻隔层内的彼此断裂的发生。在未显示相对于任何卷绕之前的板在阻隔性能上有任何降低的情况下,如图1中所示的板100(有或没有掩膜102)已围绕15mm直径的心轴卷绕10000转。
尽管以上讨论主要针对具有25μm量级的厚度的非常薄的前子组件,但可以通过增加子组件的厚度来增加附加的碰撞保护。这可以通过增加一个或两个PET层、层压附加层(例如,PET,PEN或聚碳酸酯)的厚度,或通过提供更厚的诸如粘附层和阻隔层的辅助层来实现。
乍看起来似乎具有类似于板100的性能的基本上单片的非层压的板可以这样制造:在单一聚合物层的相对的侧上溅射两个阻隔层,伴随紫外线吸收剂或者被提供在聚合物层中或者在非电极阻隔层(即,板100中的AlOx层)上作为附加的涂层,如果需要涂覆防眩光硬涂层并应用掩膜。然而,这样的工艺具有严重的缺陷:由于溅射和涂覆步骤在同一聚合物层上顺序实现,使在不同步骤中的生产率损失被叠加,这有可能致使所得板的价格昂贵。另外,聚合物层中局部集结差的阻隔性能的缺陷有可能影响到同一聚合物层的两侧上的阻隔层,从而使阻隔性能有很大损害。类似地,有可能在两个阻隔层中的同一位置发生由于机械应力引起的断裂。
附图的图2是通过本发明的第二多层板(总体标示为200)的横截面示意图。该板200包括厚度约2密尔(51μm)的掩膜202,以及与该掩膜202接触的防眩光硬涂层204。掩膜202和硬涂层204二者均与图1中所示的板100的相应层相同并用作相同的功能。板200还包括0.5密尔(13μm)的聚对苯二甲酸乙二酯(PET)层206;但是在板200中是该层206承载紫外线吸收剂。层206的远离硬涂层204的表面承载AlOx阻隔层208A,该层通过薄(约5μm)的固化的粘附层210被固定于第二AlOx阻隔层208B。在第二0.5密尔(13μm)的PET层212上承载阻隔层208B。最后,板200包括湿式涂覆的传导层214,其形成最终显示器的前电极。
用于制造图2中示出的板200的优选的工艺如下。该工艺开始于在其上已形成AlOx层的两个PET板;这种承载AlOx涂层的PET板可以容易地从商业上得到,且该两个板将最后形成最终板200的层206/208A和212/208B。将可固化的湿粘附剂涂覆在其中一个AlOx涂层上,且将两个PET/AlOX组合在一起,并固化粘附剂以形成板200的层206/208A/210/208B/212。将紫外线吸收剂扩散到PET层206中,并将传导层214湿式涂覆到第二PET板212的一个表面上。最后,涂覆防眩光硬涂层204到PET层206的暴露的表面上,且然后将掩膜202应用到硬涂层204的暴露的表面。
应注意的是,板200中的AlOx阻隔层208A和208B被埋在两个PET层之间,并因此得到很好地保护以免受到机械损伤。
和图1中所示的板100相同,图2所示的板200可能具有许多变化。针对板100提到的所有变化也可以在板200中实现。另外,可以将紫外线吸收剂合并到一个PET层。如果需要可以省略掩膜202。在一些应用中还可能省略硬涂层204,留下PET层206的一个表面作为板100的观看面。根据用于紫外线辐射的特定的电光媒质的敏感性,以及显示器可能的预期的使用,可以从PET层206中省略紫外线吸收剂,或以其它方式提供紫外线吸收,如前述的2007/0109219所描述。AlOx阻隔层可以由具有足够透明度和阻隔性能的任何溅射的或蒸发的金属或陶瓷层或聚合物来替代;适合的材料的例子包括ITO、铝、氧化硅、碳化硅以及在注册贸易商标CLARIS,ACLAR和SARAN下市售的均聚物。类似地,传导层216可以由具有足够透明度和传导性的任何溅射的或蒸发的金属或陶瓷层或聚合物来替代;适合的材料的例子包括铝、诸如PEDOT(聚(3,4-乙烯基二氧噻吩)的传导性聚合物以及碳纳米管。在板200中,为了减少生产率损失,装配的顺序很重要。
如以上所说明的,在图1所示的板100中,ITO层114提供传导和阻隔功能。相反,诸如板200中的层216的湿式处理的传导层典型地具有差的阻隔性能。相应地,为了保持出色的阻隔性能,板200被提供有两个AlOx层208A和208B(与板100中的单一的AlOx层108相比)以提供类似于板100中通过AlOx层108和ITO层114的组合来提供的阻隔性能。在板200中提供两个AlOx层208A和208B是经济可行的,这是因为涂覆有AlOx的聚合物膜价格相对低廉,而ITO却昂贵。板200的机械性能非常类似于膜100的机械性能。
从以上可以看出,本发明提供用在电光显示器中的具有出色阻隔性能的机械上坚固的前子组件。可以容易地对诸如防眩光硬涂层、紫外线吸收剂的特性、所采用的掩膜的厚度及类型(如果有)进行改变以适应不同的客户需求。
从在前讨论中显而易见的是,本发明的膜可以与具有该膜能够粘附到的固态外表面的任何电光层一起使用。相应地,可以采用以上所述的任何类型的电光媒质来实施本方法。例如,本方法可以采用旋转双色元件、电致变色或电泳媒质,且在最后的情况中电泳媒质可以是封装的、聚合物分散的或微单元的类型。使用本发明的膜生产的显示器可以用在使用现有技术的固态电光显示器的任何应用中。因此,本发明例如可以使用在电子书阅读器、便携式计算机、平板计算机、移动电话、智能卡、标牌、手表、货架标签或闪存驱动器中。
Claims (17)
1.一种在电光显示器中用作前子组件的多层膜(100;200),该多层膜(100;200)的特征在于按顺序地包括:
透光导电层(114;214);
透光第一保护层(112;212);
透光湿气阻隔层(108;208A,208B);以及
透光第二保护层(106;206)。
2.根据权利要求1所述的膜,其中所述膜具有不超过100μm的总厚度,不包括在将该膜合并到功能电光显示器中之前移除的任何层。
3.根据权利要求2所述的膜,其中所述膜具有不超过50μm的总厚度,不包括在将该膜合并到功能电光显示器中之前移除的任何层。
4.根据任一在前权利要求所述的膜,其中所述透光导电层(114)包括铟锡氧化物。
5.根据任一在前权利要求所述的膜,其中所述透光导电层(214)包括湿式涂覆的传导层。
6.根据任一在前权利要求所述的膜,其中所述第一和第二保护层(112;206)的至少一个包括紫外线吸收剂。
7.根据任一在前权利要求所述的膜,其中所述湿气阻隔层(108;208A,2088)包括氧化铝。
8.根据任一在前权利要求所述的膜,进一步包括在所述第二保护(106;206)层的与所述透光导电层(114;214)相对的侧上的防眩光硬涂层(104;204)。
9.根据任一在前权利要求所述的膜,进一步包括在所述第二保护(106;206)层的与所述透光导电层(114;214)相对的侧上的掩膜(102;202),所述掩膜从与它接触的层可移除而对该层基本没有损伤。
10.根据任一在前权利要求所述的膜,进一步包括布置在所述第一保护层(112)和所述湿气阻隔层(108)之间的粘附层(110)。
11.根据权利要求1至10之一所述的膜,其中所述湿气阻隔层包括通过非阻隔中间层(210)分离的第一和第二湿气阻隔子层(208A,2088)。
12.根据权利要求11所述的膜,其中所述中间层(210)为粘附层。
13.一种用于组装电光显示器(100;200)的工艺,该工艺的特征在于:
提供多层膜(100;200),该多层膜本身顺序地包括:
透光导电层(114;214);
透光第一保护层(112;212);
透光湿气阻隔层(108;208A,208B);以及
透光第二保护层(106;206);
提供包括夹在第一和第二粘附层之间的电光媒质的层的双释放膜;
提供包括至少一个像素电极的背板,
利用与所述导电层(114;214)接触的所述第一粘附层层压所述双释放膜至所述多层膜(100;200),从而固定所述双释放膜至所述多层膜(100;200);以及
利用与所述背板接触的所述第二粘附层层压所述双释放膜至所述背板,从而固定所述双释放膜至所述背板,
所述两个层压是按二者中任一的顺序完成。
14.根据权利要求13所述的工艺,其中所述多层膜(100;200)进一步包括在所述第二保护(106;206)层的与所述透光导电层(114;214)相对的侧上的掩膜(102;202),所述掩膜(102;202)从与其相接触的层可移除而基本上不损伤所述层,并且在所述多层膜(100;200)被固定至所述双释放膜之后从所述层移除所述掩膜(102;202)。
15.根据权利要求13所述的工艺,其中所述多层膜(100;200)具有不超过50μm的总厚度,不包括在将该膜合并到功能电光显示器中之前移除的任何层,并且所述层压的多层膜(100;200)、双释放膜和背板的总厚度不超过150μm。
16.一种用于制备在电光显示器中用作前子组件的多层膜(100)的工艺,该工艺的特征在于:
提供第一聚合物板(112),其包括紫外线吸收剂并在其一个表面上具有透光导电层(114);
提供第二聚合物板(106),该第二聚合物板在其一个表面上具有湿气阻隔层(108);
涂覆粘附层(110)至所述第二聚合物板(106)的涂覆有所述湿气阻隔层的表面上或没有承载所述导电层(114)的所述第一聚合物板(112)的表面上;以及
将所述第一(112)和第二(106)聚合物板接触在一起,其中所述导电层(114)被暴露,并且所述粘附层(110)和所述湿气阻隔层(108)布置在所述两个聚合物板(112,106)之间。
17.一种用于制备在电光显示器中用作前子组件的多层膜(200)的工艺,该工艺的特征在于:
提供各自包括聚合物层(206,212)的第一和第二聚合物板,所述聚合物层(206,212)在其一个表面上具有湿气阻隔层(208A,208B);
在一个所述湿气阻隔层(208A,208B)上涂覆粘附层(210);
将所述第一和第二聚合物板接触在一起,其中所述粘附层(210)和所述两个湿气阻隔层(208A,208B)布置在所述两个聚合物层(206,212)之间;
引入紫外线吸收剂到一个所述聚合物层(206)中;以及
在一个所述聚合物层(212)的暴露的表面上形成传导层(214)。
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Cited By (2)
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CN103137245A (zh) * | 2011-11-30 | 2013-06-05 | 群康科技(深圳)有限公司 | 透明导电膜及其制造方法、电子装置 |
CN103137245B (zh) * | 2011-11-30 | 2015-09-09 | 群康科技(深圳)有限公司 | 透明导电膜及其制造方法、电子装置 |
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WO2008091850A3 (en) | 2009-12-30 |
US20100118384A1 (en) | 2010-05-13 |
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HK1143424A1 (en) | 2010-12-31 |
WO2008091850A2 (en) | 2008-07-31 |
US20080174853A1 (en) | 2008-07-24 |
EP2111562A2 (en) | 2009-10-28 |
US20110286086A1 (en) | 2011-11-24 |
US8498042B2 (en) | 2013-07-30 |
US8009344B2 (en) | 2011-08-30 |
KR20090102823A (ko) | 2009-09-30 |
EP2111562B1 (en) | 2018-09-19 |
KR101256709B1 (ko) | 2013-04-19 |
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CN101836167B (zh) | 2013-11-06 |
EP2111562A4 (en) | 2012-02-08 |
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