CN101553751B

CN101553751B - Components and methods for use in electro-optic displays

Info

Publication number: CN101553751B
Application number: CN2007800350893A
Authority: CN
Inventors: G·M·丹纳; V·C·诺思罗普; S·里法伊; S·F·帕特里
Original assignee: E Ink Corp
Current assignee: E Ink Corp
Priority date: 2006-09-20
Filing date: 2007-09-07
Publication date: 2012-04-11
Anticipated expiration: 2027-09-07
Also published as: WO2008036511A3; EP2064581A2; WO2008036511A2; JP5337699B2; HK1132553A1; JP2013130889A; CN101553751A; JP2010504557A; EP2064581A4

Abstract

A sub-assembly for use in forming an electro-optic display comprises (in this order) a light-transmissive substrate (120); discrete areas (204) of electro-optic material separated by gutter areas (205) essentially free from the electro-optic material; and an adhesive layer (122) and/or a release layer (124) peelable from the sub-assembly. A second sub-assembly comprises (in this order) a peelable release sheet (102); discrete areas of electro-optic material (204) separated by gutter areas (205) essentially free from the electro-optic material, and an adhesive layer (206) and/or a peelable release layer (208). Processes for producing these sub-assemblies and for using them to form electro-optic displays are also described.

Description

Be used in parts and method in the electro-optic displays

The cross reference of related application

The application relates to: (a) the open No.2006/0291034 of United States Patent (USP); (b) United States Patent(USP) No. 7,236, and 292; (c) United States Patent(USP) No. 6,982, and 178; (d) the open No.2004/0155857 of United States Patent (USP); (e) United States Patent(USP) No. 7,110, and 164; (f) the open No.2007/0109219 of United States Patent (USP); (g) the open No.2007/0152956 of United States Patent (USP); (h) international application No.PCT/US2007/063551; (g) international application No.PCT/US2006/061141.

For ease, after this aforesaid patent, open and application can be called " electro-optic displays manufacturing " or " EODM " patent.

Technical field

The application relates to parts and the method that is used in the electro-optic displays.More specifically, the application relates to the method for the manufacturing that is used for electro-optic displays and some sub-components that in such method, produce.The present invention relates generally to such method and the sub-component that is used to form electro-optic displays; This electro-optic displays comprises solid-state electro-optical medium (this class display is referred to as " solid electro-optic display " hereinafter for ease) under it has the meaning of solid-state outside surface, although medium can and have the space that internal liquid or gas are filled usually really; The invention still further relates to the method for utilizing such electro-optical medium assembled display.Therefore, term " solid electro-optic display " comprises the display of other type of LCD and the following stated of electrophoretic display device (EPD), the encapsulation of encapsulation.

Background technology

Background term and state about the electro-optic displays technical field have at length been discussed in aforesaid EOMD patent, can be with reference to these patents in order to obtain the more information reader.Therefore, will carry out brief summary to this term and the state of this area below.

The term " electric light " that is applied in material or display as used herein is its conventional sense in technical field of imaging; Refer to material with first and second show states; At least a optical property of this first and second show state is different, makes this material be converted to second show state from first show state through apply electric field to this material.

The term " bistable " that here uses and " bistability " are its routine meanings in the art; Be meant the display that comprises display element with first and second show states; Said first and second show states have at least a kind of optical property different; Make any point element be driven into and present its first or second show state through addressing pulse with finite duration; After addressing pulse stopped, it was several times of times of minimum duration that change the required addressing pulse of state of this display element, for example at least four times of times at least that this state will continue.

The electro-optic displays of known several types, for example: (a) Rotating Double color component display (for example referring to, United States Patent(USP) 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; With 6,147,791); (b) electrochromic display device (ECD) (for example referring to, O ' Regan, people's such as B. Nature1991,353,737; Wood, the Information Display of D., 18 (3), 24 (March 2002); Bach, people's such as U. Adv.Mater., 2002,14 (11), 845; With United States Patent(USP) No. 6,301,038,6,870,657 and 6,950,220); (c) the wet display of electricity (referring to Hayes, people's such as R.A. " Video-Speed ElectronicPaper Based on Electro wetting ", Nature, 425, the open No.2005/0151709 of 383-385 (25 September2003) and United States Patent (USP)); (d) based on the electrophoretic display device (EPD) of particle, wherein a plurality of charged particles move through fluid (referring to United States Patent(USP) No. 5,930,026 under electric field effects; 5,961,804; 6,017,584; 6,067,185; 6,118,426; 6,120,588; 6,120,839; 6,124,851; 6,130,773; With 6,130,774; The open No.2002/0060321 of U.S. Patent application; 2002/0090980; 2003/0011560; 2003/0102858; 2003/0151702; 2003/0222315; 2004/0014265; 2004/0075634; 2004/0094422; 2004/0105036; 2005/0062714; With 2005/0270261; With the open No.WO 00/38000 of international application; WO 00/36560; WO 00/67110; With WO 01/07961; With European patent No.1,099,207 B1; With 1,145,072 B1; With the MIT that in aforesaid United States Patent(USP) No. 7,012,600, discusses and other patents and the application of E Ink).

The several different variants that have electrophoretic media.Electrophoretic media can be used liquid state or gaseous fluid; Referring to such as Kitamura; T. wait " motion of electronics toner in the electrical type paper display " (" Electrical toner movement for electronic paper-like display ") of people, IDW Japan, 2001; Paper HCS1-1; And Yamaguchi, " utilizing the toner display of the insulating particle of static electrification " of people such as Y. (" Toner display using insulative particlescharged triboelectrically "), IDW Japan; 2001, Paper AMD4-4.The open No.2005/0001810 of United States Patent (USP); European patent application 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 and 1,598,694; And International Application No. WO 2004/090626, WO2004/079442 and WO2004/001498.Medium can be packed, comprises many folliculus, in wherein each folliculus comprises itself mutually and around the cyst wall of interior phase, but contain the particle that is suspended in the electrophoresis motion in the liquid suspension medium in wherein said mutually.Typically, these capsules itself are kept in the polymeric binder to form the adhesion layer between two electrodes, referring to patent and the application of aforesaid M I T and E INK.Alternative; The wall around separating micro-capsule in the electrophoretic media of encapsulation can be used continuous replacement mutually; Thereby produce so-called dispersed polymeres (polymer-dispersed) electrophoretic display device (EPD), wherein electrophoretic media comprises droplet and the external phase of polymeric material of the separation of a plurality of electrophoretic fluid, for example referring to United States Patent (USP) NO.6; 866,760.For the application's purpose, the subclass of the electrophoretic media that the electrophoretic media of this polymer dispersed is considered to encapsulate.Another kind of variant is so-called " microcell electrophoretic display ", and wherein, charged particle and fluid remain in a plurality of chambeies that are formed in the carrier medium that is generally polymer film, for example referring to United States Patent (USP) NO.6, and 672,921 and 6,788,449.

Electrophoretic media can be with " shutter mode (shutter mode) " work, and a kind of show state is that opaque and a kind of show state is a printing opacity basically under this pattern.For example referring to aforesaid United States Patent(USP) No. 6,130,774 and 6,172,798, and United States Patent(USP) No. 5,872,552,6,144,361,6,271,823,6,225,971 and 6,184,856.Dielectrophoretic displays also can be with similar pattern work; Referring to United States Patent(USP) No. 4,418,346.The electro-optic displays of other types also can be with shutter mode work.

For example the electro-optical medium of other type of the liquid crystal medium of encapsulation also can be used in the method for the invention.

Usually, electrophoretic display device (EPD) comprises one deck electrophoresis material and at least two other layers that are arranged on this electrophoresis material opposite side, and this two-layer one of them is an electrode layer.The two-layer electrode layer that is in most of this displays is with this two electrode layers or one of them patterning, so that limit the pixel of display.For example, an electrode layer is patterned as elongated column electrode, another electrode layer is patterned as elongated row electrode, extend with the rectangular direction of column electrode on this row electrode edge, and then pixel is limited the point of crossing of row with the row electrode.Alternatively, and more usually, an electrode layer has the form of single continuous electrode, and another electrode layer is patterned as the matrix of pixel electrode, and each pixel electrode limits a pixel of display.Another kind of type be intended to adopt contact pilotage, printhead or similarly and in the electrophoretic display device (EPD) of the travelling electrode of displays separated; Have only one deck of a plurality of layers of contiguous this electrophoresis layer to comprise electrode, at the layer of electrophoresis layer opposite face usually as protective seam to prevent travelling electrode infringement electrophoresis layer.

The method of lamination that being used for of most prior art need be used for forming each layer of electro-optic displays is essentially batch method (batch methods); Electro-optical medium, lamination adhesive and backboard only are that combination just is put into together before being about to finally in the method, so this just need be applicable to mass-produced method better.

Aforesaid United States Patent(USP) No. 6,982,178 has been described a kind of combination solid electro-optic display method of (comprising the electrophoretic display device (EPD) based on particle), and this method can be applicable to a large amount of productions preferably.This patent has been described basically so-called " frontal plane lamination (front plane laminate) " (" FPL "), should " frontal plane lamination " the order solid-state electro-optical medium of one deck, adhesion layer and the release board (release sheet) that comprise the printing opacity conductance layer, electrically contact with conductance layer.Typically, this printing opacity conductance layer is contained on the light-transparent substrate, and said light-transparent substrate is preferably flexible, this flexibility this substrate can manually be wound on diameter be on 10 inches (254 millimeters) (for example) rotating cylinders and can the meaning of permanent strain on.Reach the specified layer of the employed term of this patent " printing opacity " expression here and can observe the variation on the show state of electro-optical medium so that the observer can pass this layer, and common this variation is to watch through conductance layer and contiguous substrate (if any) through enough light.Substrate is generally polymer film, and its thickness is preferably about 2 to about 10 Mills (51 to 254 μ m) about 1 to the scope of about 25 Mills (mil) (25 to 634 μ m) usually.Aptly, conductance layer is thin metal or the metal oxide layer such as aluminium or ITO, or is conducting polymer.Polyethylene terephthalate (PET) film that is coated with aluminium or ITO is commercial obtainable; For example from du pont company (the E.I.du Pont de Nemours & Company of Wilmington, the Delaware State; Wilmington DE) " calorize steps and draws (Mylar) " (" Mylar " is registered trademark), this commercial materials is used in the frontal plane lamination can have good effect.

Can realize utilizing the combination of the electro-optic displays of this frontal plane lamination through such mode: with release board in the past the plane lamination remove; Adhesion layer is contacted with backboard impelling adhesion layer to adhere under the condition of backboard effectively, thereby the layer and the conductance layer of adhesion layer, electro-optical medium is fixed to backboard.This technology can be adapted to a large amount of productions well, and this is because the frontal plane lamination generally is to adopt the takeup type coating technique and mass-produced, is cut to then in order to use the piece of required arbitrary dimension with specific backboard.

Aforesaid 2004/0155857 has described so-called " two release board ", is somebody's turn to do the simplification version that " two release board " is essentially the frontal plane lamination of aforesaid United States Patent(USP) No. 6,982,178.A kind of form of two release boards comprises that one deck is clipped in the solid-state electro-optical medium between two adhesion layers, and one of them or two adhesion layers are covered by release board.The another kind of form of two release boards comprises that one deck is clipped in the solid-state electro-optical medium between two releasing layers.Two release films of these two kinds of forms all be intended to be used in be substantially similar to described be used in the past that the plane lamination comes in the middle of the technology of combined electrical optical display unit, but relate to the lamination of two separation, usually; In first time lamination; Electrode in second time lamination, was laminated to backboard to form final display with preceding sub-component then to form preceding sub-component before two release boards were laminated to; If but expectation, the order of this twice lamination can be put upside down.

Aforesaid 2007/0109219 has described so-called " inverted frontal plane lamination ", and it is at aforesaid United States Patent(USP) No. 6,982, the distortion of the frontal plane lamination described in 178.This inverted frontal plane lamination sequentially comprises: at least one in light transmission protective layer and the printing opacity conductance layer, adhesion layer, solid-state electro-optical medium layer and release board.This inverted frontal plane lamination is to be used to form the electro-optic displays that between electrooptic layer and preceding electrode or preceding substrate, has the lamination adhesion layer; Between electrooptic layer and backboard, can have maybe can the second not thin usually adhesion layer.The cryogenic property that the resolution that this electro-optic displays has concurrently is become reconciled.

Yet, in the large scale manufacturing of electro-optic displays, also have many problems.The slow relatively and therefore labour intensive of related lamination process; Therefore in fact, at least for low-cost display, need to use " All-in-One " method; The a plurality of displays of this method lamination in single operation are separated from each other each display in the later phases of technology.In order to allow suitable separation, must between adjacent displays, leave gap (" groove ").If electro-optical medium is applied in the substrate as continuous film, the electro-optical medium in groove is wasted, because it is not used in any one of final display.Because electro-optical medium is expensive, such waste is serious problem, especially when single display hour, for example is used in the electro-optic displays that flicker drives.For example, the lamination of small displays can cause only about 20% of electro-optical medium to be included in the final display, and remaining about 80% is wasted.If do not want electricity wasting optical media in groove, must accurately keep the each interval of the discrete sheet (with other layer that before lamination, adheres to above that) of electro-optical medium to make these discrete sheets can be laminated to the miscellaneous part of final display.

Summary of the invention

The present invention provides the method for the production that is used for electro-optic displays that reduces or eliminates foregoing problems.The present invention also is provided at some useful in such method sub-components.

On the one hand, the present invention is provided for forming (first) sub-component of electro-optic displays, and this sub-component comprises: light-transparent substrate; Be arranged in a plurality of zone of dispersions of suprabasil adhesion material, said zone of dispersion is separated from one another through the trench region that does not have adhesion material substantially; Be arranged in a plurality of zone of dispersions of the electrooptical material on the adhesion material; Each of the zone of dispersion of electrooptical material is arranged on of a plurality of zone of dispersions of adhesion material, and the zone of dispersion of said electrooptical material is separated from one another through the trench region that does not have electrooptical material substantially; With on the opposite side with respect to the zone of the electrooptical material of substrate, at least one of adhesion layer and releasing layer can be peeled off and it does not had the essence damage from sub-component.

This first sub-component of the present invention can have second adhesion layer that contacts with the zone of electrooptical material and with respect to the releasing layer of electrooptical material on the opposite side of adhesion layer.Adhesion layer and/or releasing layer can extend or not extend across trench region.Substrate can comprise light transmission conductive layer.First sub-component can also comprise the removable masking film that is arranged in respect on the opposite side of the substrate of electrooptical material.

The present invention also provides a kind of (second) sub-component that forms in the electro-optic displays that is used in, and said sub-component comprises: release board; Be arranged in a plurality of zone of dispersions of suprabasil electrooptical material, said zone of dispersion is separated from one another through the trench region that does not have electrooptical material substantially; Said release board can peel off and it not had essence damage from electrooptical material; With with respect on the opposite side in the zone of the electrooptical material of release board, at least one of adhesion layer and releasing layer, said releasing layer can peel off from electrooptical material or the adhesion layer that is in contact with it, and it is not had the essence damage.

This second sub-component of the present invention has the adhesion layer that contacts with the zone of electrooptical material and with respect to the releasing layer of electrooptical material on the opposite side of adhesion layer.Adhesion layer and releasing layer can extend across or not stride across trench region, but the latter is normally preferred.

The solid electro-optic material of any type of discussing above first and second sub-components of the present invention can utilize.Therefore, for example, the sub-component of arbitrary type can comprise Rotating Double color component or electrochromic material.Alternative, the sub-component of arbitrary type can comprise having and is arranged in the fluid and electrophoresis material that can under electric field effects, move through a plurality of charged particles of fluid.Charged particle and fluid are limited in a plurality of capsules or the micro unit.Alternative, charged particle exists as the continuous a plurality of discrete droplet that surrounds mutually that is comprised polymeric material with fluid.Said fluid can be liquid or gaseous state.[023] on the other hand; The present invention provides a kind of (first) process that is used to form first sub-component of the present invention; Said process comprises: form a plurality of parts, each parts comprises one deck electrooptical material and can peel off from the layer of electrooptical material and it is not had the releasing layer of essence damage; Arrange said a plurality of parts on stayed surface, said parts each interval, the layer of electrooptical material is stayed surface dorsad; With effectively causing said a plurality of parts to adhere under the condition of substrate, a plurality of parts of being arranged are contacted with light-transparent substrate.

In first process of the present invention, stayed surface can comprise the mould with a plurality of depressions, and wherein said parts are accommodated in said a plurality of depression.Each of parts also comprises with respect at least one of adhesion layer and releasing layer and is arranged in the substrate adhesion layer on the opposite side of layer of electrooptical material; And said parts are disposed on the said stayed surface; Wherein the substrate adhesion layer makes the substrate adhesion layer play a part parts are adhered to substrate towards substrate.Said first process also comprises: in second substrate, form the sub-component that comprises adhesion layer; And after parts are adhered to light-transparent substrate, remove releasing layer and effectively causing said parts and light-transparent substrate to adhere under the condition of adhesion layer, the second suprabasil adhesion layer contact that coexists of said parts from parts.The substrate that is used in first process comprises light transmission conductive layer.

On the other hand, the present invention provides a kind of (second) process that is used to form first sub-component of the present invention, and this second process comprises: on release board, form one deck electrooptical material; The electro-optical material layer that is breaking on the release board is passed through trench region a plurality of zone of dispersions separated from one another to limit; Remove the layer of electrooptical material from trench region, and stay the electrooptical material on the release board in a plurality of zone of dispersions; With, after the layer of said electrooptical material removes from trench region, adhere to light-transparent substrate to the electrooptical material in a plurality of zone of dispersions.

This second process of the present invention can also comprise: the adhesion layer that on release board, forms the layer that covers electrooptical material; The layer of cut-out electrooptical material and adhesion layer are to limit a plurality of zone of dispersions; Remove the layer and the adhesion layer of electrooptical material from trench region; With at the layer of said electrooptical material with after adhesion layer removes from trench region, the adhesion layer that light-transparent substrate is coexisted in a plurality of zone of dispersions contacts, thereby causes light-transparent substrate to adhere to adhesion layer.

Alternative or additional, second process of the present invention can also comprise: the releasing layer on the adhesion layer that covers on the release board is provided; The layer, adhesion layer and the said releasing layer that cut off electrooptical material are to limit a plurality of zone of dispersions; With before light-transparent substrate is contacted with adhesion layer, remove releasing layer from a plurality of zone of dispersions and trench region.Removing of releasing layer can realize two stages; In the said phase one said releasing layer is removed from said trench region; Stay the said releasing layer of the layer that in said a plurality of zone of dispersions, covers said adhesion layer and electrooptical material and said releasing layer is removed from the layer of adhesion layer a plurality of zone of dispersions and said electrooptical material in subordinate phase.

The another kind of form of second process of the present invention also comprises: on second release board, form the sub-component that comprises adhesion layer; With behind the electrooptical material that light-transparent substrate is adhered in a plurality of zone of dispersions, remove release board from the layer of electrooptical material, and with the adhesion layer contact of electrooptical material, thereby adhere to the layer of said sub-component to said electrooptical material with said sub-component.

In second process of the present invention; On said a plurality of zone of dispersions and said trench region and after this layer of said electrooptical material is that plate through placing material will be with the plate of the said material of the part of electrooptical material from removing with trench region that it adheres to mutually from removing of said trench region, and the electrooptical material that stays in said a plurality of zone of dispersions is realized.Alternative; Cutting off the layer of said electrooptical material, said adhesion layer and said releasing layer with after limiting said a plurality of zone of dispersion; The part of the releasing layer in said trench region can be removed at first; And after this plate of material is placed on said a plurality of zone of dispersion and the said trench region; And after this will be, and stay said adhesion layer and the said electrooptical material in said a plurality of zone of dispersions with the plate of the said material of the part of adhesion layer and electrooptical material from removing with trench region that it adheres to mutually.Removing of the plate of said material can also remove said releasing layer from said a plurality of zone of dispersions.Said substrate can comprise light transmission conductive layer.

Description of drawings

Figure 1A to 1E illustrates the schematic side elevation of each state of a kind of form of first technological process of the present invention of producing first sub-component of the present invention.[031] Fig. 2 A to 2F illustrates the schematic side elevation of each state of a kind of form of second technological process of producing first and second sub-components of the present invention.

Fig. 3 A to 3D is illustrated in the schematic side elevation of each state of the improved form of second technological process of the present invention shown in Fig. 2 A to 2F, and this improved technological process is produced first and second sub-components of the present invention once more.

Embodiment

To describe " pine " and " tightly " release board below.These terms look like with their routine in the art and use, and are used to show need be used for from the layer that contacts with the release board amplitude with its power of peeling off, the power that tight release board need be bigger than loose release board.Special, if stack layer has tight release board and has loose release board at opposite side in a side, maybe loose release board be peeled off from stack layer and tight release board do not separated from stack layer.

As pointed out, sub-components more of the present invention comprise the adhesion layer of two separation.When needs or expectation, two adhesion layers will be denoted as " preceding " and " back " adhesion layer, and these terms indicate the position of associated adhesion layer in the final display that produces through laminate sub to backboard; Before adhesion layer be that to be positioned at the observation of electro-optical medium and display surperficial (promptly; The observer is through the surface of its observation display; Be generally away from the surface of backboard and be considered to " preceding " of display) between adhesion layer; Then adhesion layer is positioned at the opposite side with respect to preceding adhesion layer of electrooptic layer, and contiguous backboard.Under normal conditions; Promptly; Display at electrooptic layer and observe have between the surface single before electrode and on the backboard with so opposite side at electrooptic layer on have under the situation of a plurality of pixel electrodes; Preceding adhesion layer is between electrooptic layer and preceding electrode, and then adhesion layer is between electrooptic layer and pixel electrode.

The size of accompanying drawing is not an accurate dimension.Special, for the ease of explaining, the thickness of each layer has been greatly exaggerated with respect to their breadth wise dimension.The present invention is well suited for production thin, flexible electro-optic display; Typically; (under the situation that does not keep release board, measure as the sub-component of the product of the technological process that describes below or the thickness that the frontal plane lamination will have about 100 μ m; Wherein release board is dropped before the backboard finally being laminated to), and can be laminated to the flexible back plate of similar thickness.

As pointed out, accompanying drawing illustrates each stage of three different process processes of the present invention, the final generation of all processes first sub-component of the present invention; Second technological process shown in Fig. 2 A-2F also produces second sub-component of the present invention.Therefore, think that such description is a most convenient, that is, at first describe each sub-assemblies of the present invention that produces by these processes, and this described the possibility that is produced these sub-components by the rapid technological process of multistep of the present invention afterwards.

By shown in first sub-component of the present invention that produces of technological process shown in Fig. 1 D, 1E, 2E and 2F in the accompanying drawing; As explained below, the 3rd technological process shown in Fig. 3 A-3D is final to be produced and those the first identical sub-components shown in Fig. 2 E and the 2F.At first sub-component shown in Fig. 1 E and the 2F is the particular form of the inverted frontal plane lamination of description in aforesaid 2007/0109219; Other first sub-component (not shown) of the present invention can be the particular forms like " tradition " (that is non-inversion) frontal plane lamination of in aforesaid United States Patent(USP) No. 6,982,178, describing.

In each of Fig. 1 D, 1E, 2E and 2F, first sub-component of the present invention comprises light-transparent substrate 120.Substrate 120 is typically sandwich construction and generally includes the euphotic electrode layer of the preceding electrode that forms final display, for example tin indium oxide (ITO) layer; This electrode layer does not illustrate separately in the accompanying drawings.Yet, can use the substrate 120 that does not have electrode layer, for example in being intended to use contact pilotage or electro-optic displays that similarly outer electrode writes.

First sub-component of the present invention also comprises a plurality of zone of dispersions (being 104, is 204) of the electrooptical material that is arranged in the substrate 120 in Fig. 2 E and 2F in Fig. 1 D and 1E.It (is 106 in Fig. 1 D and 1E that shown sub-component has substrate (or preceding) adhesion layer; Be 206 in Fig. 2 E and 2F) be inserted in

electrooptical material

104 or 204 and substrate 120 between, but in some cases, this preceding adhesion layer can save; The electrooptical material that for example comprises the bonding agent that himself plays adhesive attraction through use; As at aforesaid United States Patent(USP) No. 7,110, described in 164.Trench region through not having electrooptical material and

adhesion layer

106 or 206 of

electrooptical material

104 or 204 zone of dispersion (in Fig. 1 D and 1E 105, in Fig. 2 E and 2F 205) is separated from one another.Though each accompanying drawing only illustrates two zone of dispersions of the electrooptical material that is separated by single trench region, in fact each sub-component has the zone of dispersion of a large amount of electrooptical materials usually; For example, the sub-component that is intended to be used to produce six independent displays possibly have 3 * 2 such zones of arranging, by two parallel trench regions and separated from one another with these two trench regions the 3rd trench region that direction extends that meets at right angles.Really; As below in greater detail; Sub-components more of the present invention can be the forms of the continuous net of limit for length's degree not, and it has a large amount of electrooptical material zone of arranging and separated by two groups of trench regions that extend with vertical direction each other with two-dimensional array.

First sub-component of the present invention also comprises adhesion layer and with respect at least one of the releasing layer on the opposite side of the layer of the electrooptical material of substrate.First sub-component shown in Fig. 1 D and the 2E only have with respect to substrate electrooptical material the layer opposite side on releasing layer 102; Yet, have the adhesion layer 122 that contacts with

electrooptic layer

104 or 204 and with respect to the releasing layer on the opposite side of adhesion layer 122 124 of

electrooptic layer

104 or 204 at Fig. 1 E and the sub-component shown in the 2F.Notice that releasing layer 102 is discontinuous in Fig. 1 D, wherein, the sheet of the separation of releasing layer 102 only covers the adjacent area of electrooptic layer 104 and does not extend across trench region 105.Yet releasing layer 102 is continuous and extends across trench region 205 in Fig. 2 E.In Fig. 1 E and 2F, adhesion layer 122 and releasing layer 124 both be continuous and extend across

trench region

105 or 205.

Second sub-component of the present invention is shown in Fig. 2 D.This sub-component comprises the release board 102 of a plurality of zone of dispersions 204 that support electrooptical material 204, and zone of dispersion 204 is not had the trench region 205 of electrooptical material separated from one another.Second sub-component also comprises with respect to release board 102 at the adhesion layer on the opposite side of electrooptic layer 206 with respect to releasing layer or the plate 208 of release board 102 on the opposite side of adhesion layer 206.Because the reason of having explained, in some cases, adhesion layer 206 can be omitted.Be discontinuous and do not extend across trench region 205 at the release board 208 shown in Fig. 2 D, if but expectation can produce and have second sub-component of the present invention that is similar to 208 continuous release board.

The method that is used to produce sub-component of the present invention will be described in detail.In the first method of the present invention shown in Fig. 1 is the generation that special but non-exclusive being intended to is used for little electro-optic displays.In the first step of technological process, electro-optical medium is coated or otherwise is deposited on the tight release board 102 to form continuous electrooptic layer 104.Individually, continuously preceding adhesion layer 106 is applied on the loose release board 108.The sub-component of two gained is laminated on together then, and wherein adhesion layer 106 contacts with electrooptic layer 104 to produce the structure shown in Figure 1A.These are as describing in aforesaid United States Patent(USP) No. 7,110,164, and the assembly of gained is two release boards, as described in aforesaid 2004/0155857.

In next step of this technological process, the sheet that is cut into suitable size at the plate shown in Figure 1A is to form independent display.Though the method such as cross cutting also can be used, the cutting routine of this plate realizes by cut, and is indicated like the line in Figure 1A 110 and 112, so that make the tongue piece 108A of loose release board 108 extend outwardly beyond other layers.At this moment, can and typically cut so that the aperture or the otch of any desired to be provided in preceding adhesion layer 106 and electrooptic layer 104 through this plate fully; For example; The aperture can through preceding adhesion layer and electrooptic layer be cut with as described in the aforesaid international application No.PCT/US2007/063551 the preformed aperture that is connected is provided; It is used to the conductive path that (as described below, with the apertures combination in the adhesion layer of back) is formed on electrode to backboard before being connected in the final display the most at last.Then, through drawing tongue piece 108A easily, with loose release board 108 from assembly removal.

Along with loose release board 108 is removed, a plurality of (in Figure 1B, being labeled as 114) of these sheets are placed in mould or the anchor clamps then, and it adheres on the side direction, and said mould or anchor clamps comprise the thin alignment sheets 116 that adheres to lamination dish 118.Alignment sheets 11 is removable and typically after 3 or 4 laminations, is dropped (the following description), yet the lamination disc type is permanent; The advantage of this configuration is alignment sheets 116 can be changed does not fast need a plurality of costlinesses so that various piece can be laminated in the same laminator a metal die.Also have, at least in some cases, typically by using the same digital document that is used for cut sheet 144 by cut such as the film formed alignment sheets 116 of the polymkeric substance of polyethylene terephthalate (PET).Should select the thickness of alignment sheets 116 to make the surface, top (adhesion) of sheet 114 extend beyond alignment sheets 116 (about 1-2mil, 25-51 μ m) a little.

As shown in Figure 1B, remain on sheet 114 in the mould 116,118 be in turn laminated to subsequently before on the excessive plate of substrate 120 (that is, greater than alignment sheets 116).Before substrate 120 are sandwich constructions of the tin indium oxide (ITO) layer that comprises the preceding electrode that forms final display.Preceding substrate also comprises removable masking film, and being described below, it was removed before final display is placed use.

This preceding underlying structure is designed to provide the preceding euphotic electrode of final display.Preceding substrate 120 also provides the essential mechanical support of and preceding electrode of relatively frangible thin for this.In addition, some electrooptic layer of expectation protection is electrophoresis layer especially, and preceding substrate preferably provides the barrier of all essential water vapor and oxygen, and ultraviolet absorption characteristic.Preceding substrate can also provide the anti-dazzle characteristic to the expectation on the observation surface of final display.Before substrate 120 have all these functions, also enough simultaneously thin and the flexible so that formation of final display enough flexibility be wrapped in (such as) on the core of 15mm diameter.As explained, preceding substrate comprises masking film; The thickness of substrate before this masking film mainly is provided for and increases is so that be convenient to operate this substrate during lamination.In preferred technological process, the gross thickness (that is, masking film is removed) that is retained in the preceding substrate in the final display is merely about 1mil (25 μ m), and increases about 2mil (51 μ m) for easy operation masking film is used to this thickness.Masking film also typically is used for during lamination, stoping scratch or dust or fragment to adhere to adjacent anti-glare layer.

After the lamination shown in Figure 1B, the plate with preceding substrate 120 of sheet fixed thereon 114 is removed from mould 116,118 as individual unit.Fig. 1 D is illustrated in the zoomed-in view of two sheets 114 in the substrate 120, forms first sub-component of the present invention together like sheet 114 and the substrate of having described 120.The substrate 120 of supporting slice 114 is placed on the laser cutting machine then, and wherein sheet 114 is towards laser instrument.Laser cutting machine be used to then to cut with the pilot hole that passes through preceding substrate 120 of the position of the position alignment of sheet 114; As described below, these pilot holes will be used to this plate is engaged with register pin with the said plate in location during lamination after a while.Alternative; Pilot hole can be precut in this preceding substrate 120 before preceding substrate 120 is laminated to sheet 114; And if so precut pilot hole were provided, they will close with the pin joint on being provided at mould 116,118 so that preceding substrate is aimed at sheet 114 during its lamination.

Divide other; Back adhesion layer 122 (Fig. 1 C) is applied on the release board 124; And the surface of the exposure of back adhesion layer is covered by middle layer (in fact, another release board-not shown in the drawings), and said middle layer is used to stop the pollution on the surface of adhesion layer during cut.Releasing layer/adhesion layer/middle layer " sandwich construction " is by cut, and wherein intermediate surface is similar to the pilot hole of those previous cuttings through preceding substrate with formation, and is intended to be used for identical purpose to laser instrument.Laser cutting machine also is used to cut needed other aperture through adhesion layer of particular display; For example, laser cutting machine can cut to be connected with the apertures of previous cutting in preceding adhesion layer and electrooptic layer and constitute the preformed aperture that is connected the aperture, as described in aforesaid international application No.PCT/US2007/063551.

In next step of this process, the middle layer is by adhesion layer 122 is removed from the back, and back adhesion layer 122 is placed on the base of laminating machine with adhesiveness release board 124 subsequently, and wherein its pilot hole engages with register pin (not shown) on the laminating machine, shown in Fig. 1 C.Tight release board 102 is peeled off from the sheet 114 that is contained in the substrate 120, and the pilot hole of previous cutting in release board 120 also with laminating machine on register pin engages, make electrooptic layer 104 exposed surface towards after adhesion layer 122.Therefore two plates are laminated on together subsequently, form inverted frontal plane lamination, as described in aforesaid 2007/0109219.Fig. 1 E be similar to Fig. 1 D's and the zoomed-in view in the part of the substrate 120 of two sheets 114 of supporting of same phase with Fig. 1 C is shown.As explained, the structure shown in Fig. 1 E constitutes first sub-component of the present invention.

At this moment be easily because remove this film before separated from one another at independent display, so masking film be removed usually, yet if expectation, removing of masking film can realize after a while.No matter whether masking film be removed, next key step is that plate is separated into a plurality of of inverted frontal plane lamination.This separation is that the cut by the plate of institute's lamination realizes, the plate of institute's lamination is maintained on the register pin to guarantee the accurate location of cutting.This cutting is cut off the 3rd release board 124, back adhesion layer 122 and preceding substrate 120 to form the sheet that separates of off-the-shelf inverted frontal plane lamination, after the 3rd release board 124 removes, is used to be laminated to backboard to form final display.Expectation to the plate of lamination cut extend beyond with the tongue piece that stays the 3rd release board before substrate 120, adhesion layer 107 and 122 and electrooptic layer 104; Such tongue piece is convenient to during the generation of final display, remove the 3rd release board 124.

As shown in Fig. 2 A-2F in the accompanying drawings, second technological process of the present invention mainly is intended to be used to produce than top with reference to the bigger display of described first technological process of Figure 1A-1E; The part that is produced by second technological process is enough big, makes that the loss of the electrooptical material that exists in the trench region between adjacent displays can be allowed.Illustrate in describing like the details of second technological process that will be below, first technological process and the main difference of second technological process be second technological process do not utilize anchor clamps to be aligned in before the sheet that separates of suprabasil electro-optical medium; But in second technological process, the successive layers of electrooptical material is cut off to produce a plurality of " islands " of the electrooptical material that is separated by the trench region that does not have electrooptical material.

In Fig. 2 A, second technological process of the present invention is identical with first technological process, and wherein Fig. 2 A is identical with Figure 1A.Yet, can see that through contrast Figure 1B and Fig. 2 B following cutting step is different.The cutting step of second technological process is achieved in that wherein loose release board 108 makes loose release board 108, preceding adhesion layer 106 and electrooptic layer 104 is cut off but tight release board 102 is not cut off towards laser cutting machine and osculating (kiss cutting).Also in first technological process, also in this step, can cut the aperture (but this also can carry out after a while, as described below) of any openings that is used for alignment holes, preformed connection or other purpose.Because in some cases; Possibly in the coil type substrate, realize whole second technological process, be formed on openings in this step can comprise form along the lateral edges of the net of material and in the subsequent stage of technological process, be used as dragging of pilot hole and draw sprocket hole.

The continuous part of pine release board 108 (promptly; The subsequent stage that covers this technological process of this release board will become the part of trench region) then by manual or mechanically remove; Therefore stay the structure shown in Fig. 2 B, continuous but the preceding adhesion layer 106 and electrooptic layer 104 that cut off above wherein keeping corresponding to " island " 208 of the loose release board of final display.The next step of this technological process is the undesired part that removes preceding adhesion layer 106 and electrooptic layer 104 respectively.Because preceding adhesion layer and electrooptic layer have enough mechanical cohesion make they can by manual oneself roll and from following tight release board 102 by large stretch of removing, this removes and can realize by hand.Yet, as shown in Fig. 2 C, the preferable methods of the undesired part of adhesion layer and electrooptic layer before being used for removing, sacrificial plate 210 (it does not need viscosity) by cold breakdown to the expose portion of island 208 and preceding adhesion layer 107.Sacrificial plate 210 is removed then, the part that adhesion layer 106 and electrooptic layer 104 are not covered by island 208 before therefore removing, and stay the structure shown in Fig. 2 D.As described above; This structure comprises second sub-component of the present invention; Wherein urgent release board 102 extends upward a plurality of " table top " (mesas); Wherein table top comprises the island 208 of loose release board and the zone below preceding adhesion layer and

electrooptic layer

206 and 204 respectively of similar size, and table top passes through trench region 205 and separated from one another.As described in first technological process of describing in the above of the present invention, in some cases, for example when electrooptical material can self during as adhesive, possibly omit preceding adhesion layer 206.Also have, as should be clearly, each of these table tops will finally form independent display.(in some cases, possibly be recovered in other small displays and to abandon the preceding adhesion layer that removes on the plate 210 and the part of electrooptic layer.)

In next step; Remainder 208 quilts of pine release board are from the structure spalling shown in Fig. 2 D; And the layer of the reservation of this structure is in turn laminated on the plate of preceding substrate 120; It can be used in above-described first technological process of the present invention in identical, and can before be used for during providing stage subsequently engaging needed aperture arbitrarily with register pin etc. in this technological process.First sub-component of the present invention that obtains from this lamination is in more detailed description in the above shown in Fig. 2 E and.

Though produce by unusual diverse ways; Sub-component shown in Fig. 2 E is similar to and in first technological process of the present invention, after lamination shown in Figure 1B and cut subsequently, is produced very much, unique difference be exactly in the structure among Fig. 2 E tight release board 102 be continuous.Therefore, the remaining step of second technological process is identical with first technological process substantially.Once more, back adhesion layer 122 is coated on the 3rd release board 124, and the middle layer is applied on the adhesion layer 122 and in resulting structure, cuts the aperture of arbitrary needs.Then; The middle layer is removed; Tight release board 102 is removed from the structure of Fig. 2 E, and the film of two gained is laminated on together producing final inverted frontal plane lamination or at the sub-component shown in Fig. 2 F, its with first technological process of the present invention produced identical.

At the variant that is above-described second technological process substantially of the 3rd technological process of the present invention shown in Fig. 3 A-3D.As shown in Fig. 3 A that is equal to Fig. 2 A and Fig. 2 B respectively and the 3B, be equal to second technological process up to Fig. 3 B the 3rd technological process.Yet, in the next step of this technological process, be not to abandon plate 210, but adhesive film 310 (Fig. 3 C) is by being rolled, and adhered to the surface of the exposure of loose release board 108 and preceding adhesion layer 106.Therefore, when adhesive film 310 was removed, the undesired part of remaining loose release board 108 and preceding adhesion layer 106 and electrooptic layer 104 was removed from its place, therefore produces the structure shown in Fig. 3 D; In fact, the use of adhesive film 310 makes that substrate 120 is merged into single operation from step and the removing of loose release board subsequently of Fig. 2 B and Fig. 2 C before before being laminated to.In case produced the structure shown in Fig. 3 D, the remaining step of the 3rd technological process is identical with second step.

Should be noted that in the 3rd technological process of the present invention, it is to realize with the form of plate that all of undesired material remove, if or this technological process be to use the continuous net form of material, realize with continuous net-shaped thing form.Therefore, the 3rd technological process of the present invention is to be suitable for very much being used in continuous, the coil type substrate.

Yet, if technological process shown in Fig. 3 A-3D and the lamination that is used to form final electro-optic displays subsequently will on continuous net-shaped thing, realize, must note keeping correct aligning to each step that runs through technological process.In the moment shown in Fig. 3 D, the known position of " table top " 204,206 on release board 102 produces.If the experience of the structure shown in Fig. 3 D is similar at the lamination shown in Figure 1B so that adhere to table top to preceding substrate; And first lamination table top to backboard (being with or without the intermediate laminate of adhesion layer to electrooptic layer 204) is realized on net in preceding substrate thereafter, and this significant need guarantees that table top is endways and aims at backboard.Because between table top and the release board 102 is initial alignment, removing of this release board can destroy this aligning.Aim at backboard in order to guarantee that table top is endways; Must at first table top be sent in preceding substrate with respect to some fixing known positions of mark; And the preceding substrate with supporting table contacts with backboard then, makes to be in known the aiming at backboard in preceding suprabasil fixation mark.Needed aligning is the most easily through providing all net to draw sprocket hole and guarantee that net drawn conveying equipment by common dragging and drive to drag, and makes them maintain automatically in expectation aligned with each other.

Can understand from the discussion of front; Method of the present invention can utilize arbitrarily such electrooptic layer to realize, this electrooptic layer have adhesion layer and release board can adhere to and have enough mechanical adhesion with the film that allows to comprise electrooptic layer must operation solid outside surperficial.Therefore, this method can use the electro-optical medium of above-described any type to realize.For example, this method can be utilized the Rotating Double color component, electrochromism or electrophoretic media, and in last situation, electrophoretic media can be encapsulation, polymer dispersed or microcell type.

Claims

1. one kind is used in the sub-component that forms in the electro-optic displays, and said sub-component is characterised in that, with such order:

Light-transparent substrate (120);

Be arranged in a plurality of zone of dispersions (106 of the adhesion material in the said substrate (120); 206), said zone of dispersion (106; 206) trench region (105 through there not being adhesion material substantially; 205) separated from one another;

Be arranged in a plurality of zone of dispersions (104 of the electrooptical material on the adhesion material; 204), the zone of dispersion (104 of electrooptical material; 204) each is arranged in a plurality of zone of dispersions (106 of adhesion material; 206) on one, the zone of dispersion (104 of said electrooptical material; 204) trench region (105 through there not being electrooptical material substantially; 205) separated from one another; With

On opposite side with respect to the zone of the electrooptical material of substrate, second adhesion layer (122) and releasing layer (102; 124) at least one can be peeled off and it does not had essence damage from sub-component.

2. sub-component according to claim 1 has second adhesion layer (122) that contacts with the zone (204) of electrooptical material and with respect to the releasing layer (124) of electrooptical material on the opposite side of second adhesion layer (122).

3. sub-component according to claim 1, wherein substrate (120) comprises light transmission conductive layer.

4. sub-component according to claim 1 also comprises the removable masking film on the opposite side of the substrate (120) that is arranged in respect to electrooptical material.

5. one kind is used in the sub-component that forms in the electro-optic displays, and said sub-component is characterised in that:

Release board (102),

Be arranged in a plurality of zone of dispersions (204) of the electrooptical material on the release board (102), said zone of dispersion (204) is separated from one another through the trench region (205) that does not have electrooptical material substantially;

Said release board (102) can peel off and it not had essence damage from electrooptical material; With

On opposite side with respect to the zone (204) of the electrooptical material of release board (102); At least one of adhesion layer (206) and releasing layer (208); Said releasing layer (208) can peel off from electrooptical material (204) or the adhesion layer (206) that is in contact with it, and it is not had the essence damage.

6. sub-component according to claim 5 has zone (204) and the adhesion layer (206) that contacts with respect to the releasing layer (208) of electrooptical material on the opposite side of adhesion layer (206) with electrooptical material.

7. sub-component according to claim 6, wherein adhesion layer (206) and releasing layer (208) do not extend across trench region (205)

8. according to claim 1 or 5 described sub-components, wherein electrooptical material comprises Rotating Double color component or electrochromic material.

9. according to claim 1 or 5 described sub-components, wherein electrooptical material comprises and has the electrophoresis material that is arranged in the fluid and can under electric field effects, moves through a plurality of charged particles of this fluid.

10. sub-component according to claim 9, wherein charged particle and fluid are limited in a plurality of capsules or the micro unit.

11. sub-component according to claim 9, wherein charged particle exists as the continuous a plurality of discrete droplet that is surrounded mutually that is comprised polymeric material with fluid.

12. sub-component according to claim 9, wherein said fluid is a gaseous state.

13. process that is used to form sub-component according to claim 1; Said process is characterised in that: form a plurality of parts (114), each parts (114) comprise one deck electrooptical material (104) and can peel off and it is not had the releasing layer (102) of essence damage from electrooptical material (104);

Arrange said a plurality of parts (114) on stayed surface (118), said parts (114) each interval, the layer of electrooptical material (104) is stayed surface (118) dorsad; With

Effectively causing said a plurality of parts (114) to adhere under the condition of said substrate (120), a plurality of parts (114) of being arranged are contacted with said light-transparent substrate (120).

14. process according to claim 13, wherein said stayed surface (118) are provided with the mould (116) with a plurality of depressions, wherein said parts (114) are accommodated in said a plurality of depression.

15. process according to claim 13; Each of wherein said parts (114) also comprises substrate adhesion layer (106); And said parts (114) are disposed on the said stayed surface (118); Wherein substrate adhesion layer (106) makes that towards said substrate (120) said substrate adhesion layer (106) plays a part said parts (114) are adhered to said substrate (120).

16. process according to claim 13 also comprises:

Formation is included in the sub-component of the adhesion layer (122) in second substrate (124); With

After said parts (114) are adhered to said light-transparent substrate (120); Remove said releasing layer (102) from said parts (114); With effectively causing said parts (114) and said light-transparent substrate (120) to adhere under the condition of said adhesion layer (122), with said parts (114) said adhesion layer (122) contact in said second substrate (124) that coexists.

17. process according to claim 13, wherein said substrate (120) comprises the printing opacity conductance layer.

18. a process that is used to form sub-component according to claim 1, said process is characterised in that:

Go up formation one deck electrooptical material (104) at release board (102);

The layer that is breaking at the said electrooptical material (104) on the release board (102) is to limit through trench region (205) a plurality of zone of dispersions (204) separated from one another;

Remove the layer of electrooptical material (104) from trench region (205), and stay the electrooptical material (204) on the release board (102) in a plurality of zone of dispersions;

With, after the layer of said electrooptical material (104) removes from said trench region (205), adhere to light-transparent substrate (120) to the said electrooptical material (204) in a plurality of zone of dispersions.

19. process according to claim 18 also comprises:

Go up the adhesion layer (106) that forms the layer that covers said electrooptical material (104) at said release board (102);

The layer of cut-out electrooptical material (104) and adhesion layer (106) are to limit a plurality of zone of dispersions;

Remove the layer and the adhesion layer (106) of electrooptical material (104) from said trench region;

With at the layer of said electrooptical material (104) with after said adhesion layer (106) removes from said trench region (205); With said light-transparent substrate (120) said adhesion layer (206) contact in a plurality of zone of dispersions that coexists, thereby cause said light-transparent substrate (120) to adhere to said adhesion layer (206).

20. process according to claim 19 also comprises:

Releasing layer (108) on the said adhesion layer (106) that covers on the said release board (102) is provided;

Cut off the layer of said electrooptical material (104), said adhesion layer (106) and said releasing layer (108) to limit a plurality of zone of dispersions; With

Before said light-transparent substrate (120) is contacted with said adhesion layer (206), remove said releasing layer (108) from said a plurality of zone of dispersions and said trench region (205).

21. process according to claim 20; Removing two stages of wherein said releasing layer (108) realizes; Cause said releasing layer (108) to remove in the phase one from said trench region (205); Stay the layer (204) of the said releasing layer (208) that covers said adhesion layer (206) and the electrooptical material in said a plurality of zone of dispersions and cause said releasing layer (208) layer removing from the said adhesion layer (206) a plurality of zone of dispersions and said electrooptical material (204) in subordinate phase.

22. process according to claim 18 also comprises:

Go up the sub-component that formation comprises adhesion layer (122) at second release board (124); With

Behind the said electrooptical material (204) that light-transparent substrate (120) is adhered in said a plurality of zone of dispersions; Remove said release board (102) from the layer (204) of said electrooptical material; And with said adhesion layer (122) contact of electrooptical material (204) with said sub-component; Thereby adhere to the layer (204) of said sub-component (122,124) to said electrooptical material.

23. process according to claim 18; The layer of wherein said electrooptical material (104) is that plate (210) through placing material is gone up with said trench region (205) and after this will be with the plate (210) of the said material of the part of said electrooptical material (104) from removing with said trench region (205) that it adheres to mutually at said a plurality of zone of dispersions from removing of said trench region (205), and stays the electrooptical material (204) in said a plurality of zone of dispersions.

24. process according to claim 21; Wherein, At the layer (104), said adhesion layer (106) and the said releasing layer (108) that cut off said electrooptical material with after limiting said a plurality of zone of dispersion; The part of the releasing layer (108) in said trench region (205) is removed at first; And after this plate of material (310) is placed on said a plurality of zone of dispersion and the said trench region (205); And after this will be, and stay said adhesion layer (206) and the said electrooptical material (204) in said a plurality of zone of dispersions with the plate (310) of the said adhesion layer (106) and the said material of the part of said electrooptical material (104) from removing with said trench region (205) that it adheres to mutually.

25. process according to claim 24, removing also of the plate of wherein said material (310) removes said releasing layer (108) from said a plurality of zone of dispersions.

26. process according to claim 18, wherein said substrate (120) comprises light transmission conductive layer.