CN102439518B - 具有滤色片的电光显示器 - Google Patents

具有滤色片的电光显示器 Download PDF

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CN102439518B
CN102439518B CN201080019412.XA CN201080019412A CN102439518B CN 102439518 B CN102439518 B CN 102439518B CN 201080019412 A CN201080019412 A CN 201080019412A CN 102439518 B CN102439518 B CN 102439518B
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R·J·小波利尼
S·J·巴特斯塔
J·D·阿贝特
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Abstract

一种用于制造彩色电光显示器的方法，该方法采用包括电光层(106)和透光导电层(104)的子组件(100；200；300；402)。将该子组件层压至具有电极的背板(404，408)，其中电光层(106)被置于背板(404，408)和导电层(106)之间。将可流动材料置于子组件(100；200；300；402)上，且将滤色片阵列置于导电层(106)上并对准背板(404，408)的电极以形成彩色显示器。

Description

具有滤色片的电光显示器
本申请涉及：
(a)美国专利公开号2004/0190114；
(b)美国专利第6,864,875号；和
(c)美国专利第7,075,502号。
技术领域
本申请涉及电光显示器和用在这种显示器中的滤色片。
背景技术
在美国专利第7,012,600号中详细讨论了关于电光显示器的背景术语和技术状况，读者可参照该美国专利获得进一步信息。因此，以下对术语和技术状况作简要概述。
作为应用于材料或者显示器的术语“电光”，其在此使用的是其在成像领域中的常规含义，指的是具有第一和第二显示状态的材料，该第一和第二显示状态的至少一个光学性质不同，通过向所述材料施加电场使该材料从其第一显示状态改变到第二显示状态。尽管光学性能一般指的是可被人眼感知的颜色，但其还可以指其他光学性能，例如光的透射、反射率、发光，或在显示器被用于机器读取情况下时，指位于可见范围外的电磁波长的反射率变化意义下的伪彩色(pseudo-color)。
此处使用的术语“双稳的”和“双稳定性”取其在本领域中的常规含义，指的是包括具有第一和第二显示状态的显示元件的显示器，所述第一和第二显示状态至少有一种光学性质不同，从而在利用具有有限持续时间的寻址脉冲驱动任何给定元件以呈现其第一或第二显示状态之后，在该寻址脉冲终止后，该状态将持续至少几倍于(例如至少4倍于)改变该显示元件的状态所需的寻址脉冲的最小持续时间的时间。
已知几种类型的电光显示器，例如：
(a)旋转双色元件显示器(参见例如美国专利第5,808,783；5,777,782；5,760,761；6,054,071；6,055,091；6,097,531；6,128,124；6,137,467以及6,147,791号)；
(b)电致变色显示器(参见例如O’Regan，B.等人的Nature1991，353,737；Wood，D.的InformationDisplay，18(3)，24(2002年3月)；Bach，U.等人的Adv.Mater.，2002，14(11)，845；以及美国专利第6,301,038；6,870,657和6,950,220号)；
(c)电湿润显示器(参见例如Hayes，R.A.等人在Nature，425，383-385(2003年9月25日)中发表的标题为“Video-SpeedElectronicPaperBasedonElectrowetting”一文以及美国专利公开号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移动通过流体(参见美国专利第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号；美国专利申请公开号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；以及国际专利申请公开号WO00/38000；WO00/36560；WO00/67110和WO01/07961；以及欧洲专利第1,099,207B1和1,145,072B1号；以及在前述美国专利第7,012,600号中讨论的其它MIT和EInk的专利和申请)。
存在电泳媒质的几种不同的变形。电泳媒质可以使用液态或者气态流体；对于气态流体参见例如Kitamura，T.等人2001年在IDWJapan，PaperHCS1-1中发表的“Electricaltonermovementforelectronicpaper-likedisplay”以及Yamaguchi等人2001年在IDWJapan，PaperAMD4-4)中发表的“Tonerdisplayusinginsulativeparticleschargedtriboelectrically”；美国专利公开号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WO2004/090626；WO2004/079442和WO2004/001498。媒质可以为封装的，包含大量的小囊，每一个小囊本身包含内相以及环绕内相的囊壁，该内相包含悬浮在流体悬浮媒质中的电泳移动粒子。典型地，这些囊本身被保持在聚合物粘合剂内以形成位于两个电极之间的粘附层(coherentlayer)；参见上述的MIT和EInk专利和申请。可替代地，在封装的电泳媒质中围绕离散的微囊的壁可以由连续相代替，因而产生所谓的聚合物分散的电泳显示器，其中电泳媒质包含电泳流体的多个离散的微滴以及连续相聚合物材料；参见例如美国专利第6,866,760号。为了本申请的目的，将这样的聚合物分散的电泳媒质看作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被保留在形成在载体媒质内的多个腔内，该载体媒质通常是聚合物膜；参见例如美国专利第6,672,921和6,788,449号。
封装的电泳显示器通常不遭受传统电泳设备的聚集和沉淀的失效模式的影响并且具有另外的优点，例如可以在各种不同柔性和刚性衬底上印刷或者涂覆该显示器。(使用“印刷”一词旨在包括印刷和涂覆的所有形式，包括但并不局限于：预调式涂覆，例如小块模具型涂覆(patchdiecoating)，狭缝式或挤压式涂覆，坡流式或阶式涂覆，淋幕式涂覆；压辊涂覆，例如辊式刮刀涂覆、前向和反向辊涂覆；凹版印刷涂覆；浸渍涂覆；喷涂；弯液面涂覆；旋涂；刷涂；气刀涂覆；丝网印刷工艺；静电印刷工艺；热印刷工艺；喷墨印刷工艺以及其它类似的技术)。因此，得到的显示器可以为柔性。另外，由于显示器媒质可以是印刷的(使用各种方法)，显示器本身能够比较低廉地被制造。
尽管电泳媒质通常是不透明的(例如，由于在许多电泳媒质中，粒子基本上阻挡可见光通过显示器的透射)并且工作在反射模式下，但是可以使许多电泳显示器工作在所谓的“快门模式”下，在该模式下一种显示状态是基本上不透明的而一种显示状态是光透射的。参见例如前述的美国专利第6,130,774和6,172,798号，以及美国专利第5,872,552；6,144,361；6,271,823；6,225,971；和6,184,856号。与电泳显示器类似但是依赖于电场强度变化的介电泳显示器可以工作在类似的模式下；参见美国专利第4,418,346号。
在本发明中还可以使用其他类型的电泳媒质。
很多类型的电光媒质基本上都是单色的(monochrome)，这意味着所提供的任何媒质具有两个极端光学状态和范围在这两个极端光学状态之间的灰度。如已说明，这两个极端光学状态不必为黑和白。例如，一个极端光学状态是白，另一个是深蓝，使中间灰度为不同深浅的蓝，或者一个极端光学状态是红，另一个是蓝，使中间灰度为不同深浅的紫。
目前，对全彩色显示器的需求在不断增长，即使是那些小的便携式显示器，例如现在大部分手机上的显示器都是全彩色的。为了提供采用单色媒质的全彩色显示器，需要把滤色片阵列放置在穿过该滤色片阵列可观察到显示器的位置，或需要把能显示出不同颜色的不同电光媒质的区域相互靠近地放置。
然而，在正确的位置上把滤色片接附到电光显示器是有难度的操作。许多滤色片阵列形成在玻璃板或类似的刚性材料上，以使滤色片能保持稳定的尺寸(即使滤色片阵列的尺寸略有变形，都会导致至少一部分滤色片阵列对不准显示器的像素，从而使显示给观察者的颜色有偏差)。出于类似理由，大部分用在彩色电光显示器中的背板由刚性材料制成。把电光媒质固定至其中一个刚性板，然后一般用位于两个刚性板之间的一层聚氨酯，或其他层压粘附剂层将两个刚性板层压到一起以形成最终的显示器。层压粘附剂层的厚度可以是约25μm。层压粘附剂在室温下有粘性，因此，很难将两个刚性板层压到一起而不会在二者之间留存气囊，特别是当板的尺寸特别小时。尽管使用特殊的对准工具用以保持刚性板的平整，并在室温下施加数量级为100psig(约0.8MPa)的相当压力，但实际发现很难避免留存大量气泡。通过在充足的温度和压力条件下，使层压后的显示器从辊之间穿过，或再次在充足的温度和压力条件下蒸压(autoclaving)显示器，可以减少气泡数量或消除气泡。这种去除气泡的应急方法会显著提高显示器组件制造的成本和周期，导致既费时又费力，而且也不一定得到高质量的彩色显示器。此外，这种用于层压刚性板，典型为层压玻璃板的方法，并不是一种较好的制作方法，因为它带来很多额外的对电性能及流变性能的限制，从而使层压非常困难。
发明内容
因此，需要一种把滤色片阵列层压至背板以形成电光显示器的方法，该方法消除或至少缓解了前述问题，而本发明正提供了这样一种方法。
本发明提供了一种组装电光显示器的方法，该方法将电光层至背板的层压与滤色片阵列到背板的层压和对准分开。
因此，本发明的一方面提供一种用于制造彩色电光显示器的方法，该方法包括：
提供包括电光层和透光导电层的电光子组件；
将该电光子组件层压至包括多个电极的背板，使得电光层被置于背板和导电层之间；
将可流动材料置于导电层上；以及
将彩色滤色片阵列置于导电层上，并将彩色滤色片阵列对准背板的电极以形成彩色电光显示器。
在该方法中，一般在电光层和背板之间提供粘附剂层。然而，如果电光层至背板能达到足够的粘性，不总是需要提供这种单独的电光层，例如，从美国专利第7,110,164号中可知，在一些情况下，电光层内的聚合物粘合剂成分可用作粘附剂，因此不再需要单独的粘附剂层。
在该方法的一种实现方式中，所述电光子组件的形式是前平面层压件，该前平面层压件包括导电层、电光层以及置于电光层的与导电层相对一侧的粘附剂层，且通过将粘附剂层接触背板实现层压。前平面层压件还可包括覆盖在粘附剂层的远离电光层的表面上的释放板，且在将前平面层压件层压至背板之前移去该释放板。如美国专利第6,982,178号中讨论，释放板可包括电光层以便于测试前平面层压件的电光性能；该导电层通常可由与释放板相同的金属化聚合物膜来提供。在该方法的另一种实现方式中，电光子组件的形式为倒置的前平面层压件，该倒置的前平面层压件按顺序地包括导电层、第一粘附剂层、电光层和第二粘附剂层，且通过将第二粘附剂层接触背板实现层压。所述倒置的前平面层压件还可包括覆盖在第二粘附剂层的远离电光层的表面上的释放板，且在将倒置的前平面层压件层压至背板之前移去该释放板。
该方法的另一种变形采用了美国专利第7,561,324号中描述的所谓的“双释放膜”。该“双释放膜”实质上为前述的美国专利第6,982,178号的前平面层压件的简化版。其中一种双释放板的形式包括夹在两个粘附剂层之间的固态电光媒质层，该一个或两个(一般为两个)粘附剂层由释放板覆盖。为了在本方法中使用这种双释放膜，把其中一个释放板从双释放膜上移除并将剩余的层层压至背板，其中暴露的粘附剂层与背板接触。然后把第二释放板移除，且在第二次层压中将导电层层压至第一次层压时形成的背板/电光层子组件。可替代地，但一般不太期望的是，该层压可以以相反顺序执行，其中第一次层压把电光层固定至导电层以形成倒置的前平面层压件，第二次层压把该倒置的FPL固定至背板，如以上所述。采用双释放膜的这两种方法的变形允许相互独立地选择导电层和电光层，这从制造角度看是非常有用的；制造者的不同客户会需要不同类型的导电层但相同的电光层，为了满足客户的需要，制造者可以制造采用共同电光层的双释放膜，然后当从客户那得到具体指示后，将该双释放膜层压至被选择的导电层。
该方法的另一种变形是采用在美国专利公开号2007/0109219中描述的所谓的“倒置的前平面层压件”，其实质上是美国专利第6,982,178号中描述的前平面层压件的变形。该倒置的前平面层压件顺序地包括：透光保护层和透光导电层中的至少一个、粘附剂层、固态电光媒质层以及释放板。该倒置的前平面层压件被用于形成在电光层和前电极或前基板之间具有层压粘附剂层的电光显示器；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剂层。这种电光显示器兼具较好清晰度和低温性能。
在本发明的方法中，电光子组件还可包括置于导电层的与电光层相对侧的前基板，该前基板给导电层提供机械支撑和保护。一些情况下，需要有这种前基板，因为导电层不是自支撑的；例如，当导电层由溅射的ITO制成时，ITO的厚度一般在1μm数量级并且其不是自支撑的。前基板的厚度可以不大于50μm，期望不大于25μm；前基板保持在最终显示器中，如果它太厚，会在电光层和滤色片阵列之间带来视差问题。无论是否具有前基板，电光层组件可包括掩膜，该掩膜可用于明显增加子组件的厚度，从而便于处理子组件，且其还可用于防止对导电层和/或前基板(如果有的话)的机械损伤。在层压滤色片阵列之前移除该掩膜。掩膜的厚度可以是100-200μm，尽管如果需要的话可使用更厚的掩膜，例如用以保护背板上的集成电路。
该方法允许使用各种可流动材料以及各种在导电层和滤色片阵列之间引入该可流动材料的方法。在该方法的一个变形中，将可流动材料和滤色片阵列置于导电层上是通过以下步骤实现的：在层压至背板的电光子组件的暴露表面上设置多个隔离物，将滤色片阵列置于该多个隔离物上，在该暴露表面和滤色片阵列之间引入可固化聚合物，以及固化该可固化聚合物。该方法还可包括将可固化的边缘密封聚合物置于电光层周界的周围但在该边缘密封聚合物内留下多个空隙，固化该边缘密封聚合物以形成边缘密封，其中该边缘密封具有延伸穿过其中的多个孔，对至少一个孔抽真空，同时将其他孔中的至少一个连接至供给的可固化聚合物，从而在导电层和滤色片阵列之间吸引该可固化聚合物。
在该方法的另一个变形中，所述可流动材料为分散在导电层上的可固化聚合物，且在将滤色片阵列置于可固化聚合物上并对准后，固化该可固化聚合物以将滤色片阵列固定于导电层。在该方法的该变形中，固化聚合物有利地通过两个步骤来实现：在将滤色片阵列置于可固化聚合物上并对准后，固化可固化聚合物的多个分离部分，该可固化聚合物被处理用以从中去除气泡，且固化剩余部分的未固化的聚合物以形成最终显示器。
在该方法的再一个变形中，可流动材料为室温下(大约21℃)非粘性的粘附剂层。可替代地，该可流动材料为在最终显示器中保持不变的不可固化的材料，例如油脂，优选为硅脂。当采用这种不可固化材料时，该方法还可包括，在滤色片阵列对准后，将可固化聚合物分散在电光层和滤色片阵列的周界的周围，且固化该聚合物以形成将电光层和滤色片阵列相互固定的边缘密封。
在需要通过蒸压或其他方法从可流动材料中去除气泡的任何本发明方法中，需要在气泡去除过程中保证滤色片阵列不会相对背板而移动。尽管可以使用机械夹持装置来固定住滤色片阵列，但实际更方便地是点固化可流动材料本身，或(如果采用非可固化材料)点固化可固化边缘密封材料以相对于背板将滤色片固定就位。
用在该方法中的电光层可以是以上讨论过的任一类型。例如，电光层可包括旋转双色元件或电致变色材料。可替代地，电光材料可包括电泳材料，该电泳材料包括置于流体中的且在电场作用下能够移动通过该流体的多个带电粒子。该带电粒子和该流体可被限制在多个囊或微单元内。可替代地，该带电粒子和流体可以表现为被包括聚合物材料的连续相所围绕的多个离散的微滴。该流体可以是液态或气态。
本发明还提供一种电光显示器，按顺序地包括：
包括多个电极的背板；
电光层；
透光导电层；
非固化的、可流动材料的层；和
滤色片阵列。
在该显示器中，可流动材料可以为油脂，例如硅脂。
附图说明
图1为穿过本发明方法使用的前平面层压件的截面示意图；
图2与图1类似，为穿过本发明方法使用的倒置的前平面层压件的截面示意图；
图3与图1和图2类似，为穿过图2中的变形的倒置前平面层压件的截面示意图；
图4为采用本发明方法组装的电光显示器的顶视图，该顶视图是在该方法中间点截取的，即在把前平面层压件层压至背板后但在层压滤色片阵列之前；
图5为流程图，其示出了本发明的方法使用相同的前平面层压件和背板而方便地制造单色和彩色电光显示器的方式。
具体实施方式
如已提到，本发明提供一种用于形成电光显示器的方法，其中首先将电光层和导电层(一般采用前平面层压件的方式)层压至背板。然后，把可流动材料沉积在导电层上，并把滤色片阵列(CFA)置于导电层上，这两个步骤可以以任一顺序执行。在本方法的一些实现方式中，当CFA就位后，固化该可流动材料；在其他实现方式中，可以用非固化材料，使得材料始终不变的保留到最终显示器内。
在本方法中，期望电光层采用前平面层压件的形式。该FPL可以是美国专利第6,982,178号中描述的“经典”FPL或美国专利申请公开号2007/0109219中描述的倒置的FPL。无论哪种情况，为了使由CFA与电光层之间的间隙导致的视差与色彩的偏差最小，都期望使FPL的靠近CFA的基板是薄的。图1示意性地示出了适用于在本方法中的一般经典FPL(总体示为100)。FPL100包括薄的前基板102，其一般为由例如聚(对苯二甲酸乙二醇酯)(PET)形成的透明聚合物膜。前基板102的厚度可以为约6至约50μm；可商业购得的厚度为约13μm的膜很适合用在该方法中。使用薄的前基板很重要，因为滤色片阵列(下面描述的)与电光层被前基板的厚度(以及被下面描述的导电层的厚度，但导电层一般比前基板薄的多)间隔开，并且如果前基板的厚度过大，会遇到视差问题，从而导致彩色显示器上图像质量的下降。FPL100还包括透光导电层104，其可以由例如氧化铟锡(ITO)、碳纳米管或有机导体制成。只要导电层能足够导电来开关电光层，对导电层性质的要求就不是首当重要的了，一般电阻低于104欧姆/方块就够了。涂布ITO的PET膜可以从商业购得并且可以被用来形成FPL100的层102和104。
FPL100接下来的一层为电光层106，在此电光层106为封装的电泳层，其包括聚合物粘合剂中的囊。如前述的美国专利第6,982,178号中所描述，该电光层可被直接涂布到导电层104上。把层压粘附剂层108置于电泳层106的与基板102相对的一侧上；在例如美国专利第7,012,735和7,477,444号中讨论了合适的粘附剂。最后，FPL100包括释放板110。
图2示意了可在本方法中使用的倒置的前平面层压件200。倒置的FPL200与图1所示的经典FPL100不同的地方在于包括位于导电层104和电光层106之间的第二粘附剂层208。在前述的2007/0109219中详细讨论了包括该第二粘附剂层208的理由。
图3示意了第二种倒置的前平面层压件300，其与图2所示的倒置的FPL200不同的地方在于增加了覆盖基板102的掩膜312。如美国专利申请公开号2008/0174853所解释，把掩膜包含在薄的FPL或类似的多层膜中很有用，其便于处理该薄膜和/或在制造或显示器组件工作时为基板提供机械保护。
图1示出的FPL100还可以通过增加类似图3所示的掩膜进行改进。
如已提到，本发明方法的第一步是把FPL层压至背板；该背板可以为直接驱动型(其中每个电极配置单独导体，使得每个电极上的电压可独立控制)或有源矩阵型(其中像素电极布置成行与列的二维矩阵，其中典型地为薄膜晶体管的非线性器件与每个像素关联，并且其中每一行中的所有电极均连接至行电极，每一列中的所有电极都连接至列电极)。一些类型的电光媒质还允许使用无源矩阵背板。
图4为本发明的优选方法在FPL402(可以是以上任一类型)层压到背板(总体示为404)后的顶视图。如图4所示，背板404包括基板406，其中央部分被有源矩阵背板408占据；FPL402层压到该有源矩阵背板408上，使得FPL402的小的周界部分延伸出背板408的边缘。在靠近FPL402占据区域的基板402上提供有对准标记410。在基板406上与背板408相间隔的位置处还提供有芯片粘结区域412。
可使用前述的EInk专利和申请中描述的任何方法把FPL402层压至背板408。基本上说，把释放板110(见图1至3)从FPL剥离，且一般在升高的温度压力下把FPL层压至背板。FPL一旦被层压好就产生图4所示的中间结构，采用本发明的第一方法接附滤色片阵列。
如已提到，该方法需要在FPL和滤色片阵列之间引入可流动的液态材料。在本发明的范围内，可以使用各种方法引入可流动的液态材料。一种方法类似于用于组装液晶显示器的方法。把间隔物(spacer)(一般为具有可精确控制直径的球)和可固化聚合物的混合物分散在FPL周界以形成周界密封，但在密封时留下多个空隙。然后把CFA置于间隔物和聚合物的混合物上。一般通过把CFA上的对准标记与背板上的类似标记相对准来实现CFA相对于背板的准确定位；未固化的聚合物可以让CFA相对于背板移动。然后固化该聚合物以相对于背板固定CFA。周界密封中由上述空隙形成的一个或多个孔连接至真空系统，同时其他孔与低粘性可固化聚合物源相连，位于FPL和CFA之间的真空系统吸引该可固化聚合物。最后，低粘性可固化聚合物被固化用以形成最终显示器。一些情况下，在把FPL层压至背板后，在FPL周界形成(一般)不同的可固化聚合物的窄围缘是有益的，这种所选择的不同的可固化聚合物是为了避免显示器边缘出现开关性能问题。聚合物的窄围缘还密封FPL，从而防止填充过程中当FPL暴露在真空下时，流失水分和/或进入环境污染物。FPL的类似周界密封还可以在本发明以下描述的方法的其他变形中使用。
在本方法的一种变形中，在把FPL层压至背板后，在FPL顶部分散可固化聚合物。选择可固化聚合物分散的图案使得在FPL和要置于该FPL上的CFA之间留存的空气最少；例如该图案可以是位于FPL中心的单独的坑(puddle)、从FPL中心向外辐射的线图案，或为“X”形。然后把CFA向下施加至可固化聚合物并轻轻向下按压，使可固化聚合物扩散并形成面对面的FPL和CFA表面的整个区域。小心控制FPL上可固化聚合物的体积，使得面对面的FPL和CFA表面的整个区域能被覆盖，但不会有多余的可固化聚合物从CFA边缘漏出。此时，可以用图4中所示的那些对准标记对准CFA，大量靠近FPL周界的小面积的可固化聚合物被固化以相对背板把CFA锁定就位。然后，用蒸压或其他已知技术去除掉聚合物中的残余气泡。在去除起泡后，固化剩余面积上的未固化聚合物以形成最终显示器。
在本方法的另一种变形中，用一种“固态的”、非粘性的粘附剂把CFA粘结至FPL(“非粘性”是指在室温或约21℃下是非粘性的)。把该粘附剂置于FPL或CFA上，可把该粘附剂方便地涂布到释放板上，且在层压至FPL或CFA后马上连接其他部件。期望在粘附剂中形成粗糙图案或一些粗糙样式，这样在把FPL层压至CFA时使空气逸出。非粘性的粘附剂允许FPL和CFA相互间进行充分地相对移动，从而在把FPL用升高的温度、压力和真空中的任一个或多个方式层压至CFA之前使这二者整体对准。一些情况下，层压后的CFA/FPL组合可以在层压后重新进行充分加热以实现两个部分的最终对准。
在本方法的另一种变形中，可以把室温下有粘性的压敏粘附剂(PSA)用作可流动材料。使用这种PSA可以避免在升温下的操作存所导致的使某些显示器部件变形的风险，但缺点是一旦这些部分彼此接触上，就只能使滤色片阵列相对于背板作有限的移动。
在本方法的另一种变形中，可以使用油脂膜把FPL连接至CFA。合适的油脂包括在美国专利第5,275,680和5,371,619号中描述的硅脂。这些油脂的化学性质稳定，在较宽的温度范围内性能稳定，室温下有较长的工作寿命且在层压过程中形成的空隙较少。可以把油脂膜直接涂布在FPL或CFA上，或者把预形成(例如涂布在释放板上)的油脂膜层压到这些部分中的一个或其余部分上。然后，把这些部分放在一起且准确对准。可以通过蒸压把油脂中留存的气泡去除掉，由于油脂的粘度和流动性，这对油脂膜特别有效。因为即使在完成的显示器中油脂也可流动，因此期望在组装显示器的最后一步，把可固化聚合物分散在FPL和CFA周界周围且固化该聚合物以形成边缘密封，从而把FPL和CFA固定在相对彼此正确的位置上。如已说明，这种可固化聚合物边缘密封可以被点固化，以在从油脂中去除气泡的操作过程中保持滤色片阵列相对于背板是固定的。
如已提到，本发明把电光层(一般为FPL的形式)至背板的层压与CFA至电光层的层压分开。其进一步的优点是在单一生产线上提供了制造单色和彩色显示器的便利制程，如图5所示意。如图所示，该生产线可以被操作以取得供给的FPL502和背板504，且把它们层压到一起(如506所示)以形成背板/FPL层压件。然后将该层压件层压至CFA以形成彩色显示器，如508所示，或在FPL上层压保护层以形成单色显示器，如510所示。
综上所述，本发明提供了彩色显示器的改善的白色状态，其中仅仅对基础颜色的饱和度有较少影响，提供了平衡的色彩重现和更好的透明饱和度，且节省了在前照亮或后照亮被使用时的能量。

Claims (7)

1.一种用于制造彩色电光显示器的方法，该方法包括：
提供电光子组件，该电光子组件包括电光层和透光导电层；
将该电光子组件层压至包括多个电极的背板使得电光层被置于背板和导电层之间；以及
将滤色片阵列置于导电层上且将滤色片阵列对准背板的电极以形成彩色电光显示器，
该方法的特征在于，在将电光子组件层压至背板之后但在将滤色片阵列置于导电层上之前，将可流动材料置于导电层上，
其中将可流动材料和滤色片阵列置于导电层上是这样实现的：在导电层上设置多个隔离物，将滤色片阵列置于该多个隔离物上，在导电层和滤色片阵列之间引入可固化聚合物，然后固化该可固化聚合物。
2.根据权利要求1所述的方法，还包括将可固化的边缘密封聚合物置于电光层周界的周围但在该边缘密封聚合物中留下多个空隙，固化该边缘密封聚合物以形成边缘密封，其中该边缘密封具有延伸穿过其中的多个孔，对至少一个孔抽真空，同时将其他孔中的至少一个连接至供给的可固化聚合物，从而在导电层和滤色片阵列之间抽引该可固化聚合物。
3.一种用于制造彩色电光显示器的方法，该方法包括：
提供电光子组件，该电光子组件包括电光层和透光导电层；
将该电光子组件层压至包括多个电极的背板使得电光层被置于背板和导电层之间；以及
将滤色片阵列置于导电层上且将滤色片阵列对准背板的电极以形成彩色电光显示器，
该方法的特征在于，在将电光子组件层压至背板之后但在将滤色片阵列置于导电层上之前，将可流动材料置于导电层上，
其中所述可流动材料为分散在导电层上的可固化聚合物，且在将滤色片阵列置于该可固化聚合物上并对准后，固化该可固化聚合物以将滤色片阵列固定于导电层。
4.根据权利要求3所述的方法，其中在将滤色片阵列置于可固化聚合物上并对准后，固化可固化聚合物的多个分离部分，该可固化聚合物被处理用以从中去除气泡，且固化剩余部分的未固化的聚合物以形成最终显示器。
5.根据权利要求3所述的方法，其中电光层包括旋转双色元件或电致变色材料。
6.根据权利要求3所述的方法，其中电光层包括电泳材料，该电泳材料包括置于流体中的且在电场作用下能够移动通过该流体的多个带电粒子。
7.根据权利要求6所述的方法，其中所述流体为气态的。
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US20100225995A1 (en) 2010-09-09
KR20110132433A (ko) 2011-12-07

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