JP2007535416A - In-mold manufacturing of articles with embedded display panels - Google Patents

Abstract

The present invention relates to an article having a display panel embedded in an upper surface and a method for manufacturing the same.

Description

Cross-reference of related applications

  This application seeks to enjoy the benefit of US Provisional Application No. 60 / 476,852, filed June 6, 2003, the contents of which are hereby incorporated by reference in their entirety. Incorporated.

TECHNICAL FIELD The present invention relates to an article having a display panel embedded in an upper surface and a manufacturing method thereof.

Description of Related Art Currently, for an article having a display panel, the article and the display panel are manufactured separately and then the two members are assembled together. Assembling such articles usually requires mechanical integration (or integration) or lamination, which usually results in a large gap between the article and the display, and the overall thickness or The volume will increase. Thus, current methods cannot meet certain product requirements such as style, compactness and durability, which are particularly important features for portable devices.

Summary of the Invention

  The first aspect of the present invention is directed to an article having a display panel embedded in an upper surface. A decorative design (for example, letters (or sentences) or figures) may be displayed on the top surface.

  The second aspect of the present invention is directed to an in-mold display transfer film or foil.

  The third aspect of the present invention is directed to an in-mold display insertion film or foil. In this aspect of the invention, the display panel may be formed on a carrier film including an electrode layer.

  The display panel in the in-mold display transfer film or foil or in-mold display insertion film or foil can be any plastic (or plastic) -based (or plastic-based) display, such as polymer dispersed liquid crystal display (PDLC), cholesteric liquid crystal display (ChLCD), organic light emitting device (OLED), electrophoretic display (EPD) or other particle based (or particle based) display.

  A fourth aspect of the present invention is directed to a method for manufacturing an article according to the first aspect of the present invention.

  The present invention has a wide variety of uses. For example, the article may be a plastic cover for a cell phone or pager, the display panel embedded on the top of which can display text messages, time and date, and / or receive incoming phone calls or multiple voice mail messages Signals can be blinked or colored when informing. In fact, the present invention applies to any article made of plastic material, such as personal belongings (eg handbags or purses), toys or educational (or educational) devices, personal digital assistants (PDAs) or electronic (e-) book plastics. Cover, credit or smart card, identification card or business card, album, wristwatch, wall clock or table clock, radio or camera face (face: or the exterior of a cover, dial or control panel), car dashboard, household items ( For example, arms, dishes or bottles), laptop computer housings, and consumer electronics carrying cases or front control panels. Obviously this list is not exhaustive. Other uses will be apparent to those skilled in the art and therefore all of them are within the scope of the present invention.

  When embedding a plastic display in an article, a very good appearance is obtained by seamless (or seamless) integration. The display panel can be matched with the article surface even when the article surface is curved. This allows the display panel to look like one integral or printed article part. According to the present invention, it is possible to embed a large-area plastic display that cannot be realized by the conventional display assembly technique in an article.

  Various aspects of the invention are illustrated in the following detailed description and the accompanying drawings.

Detailed Description of the Invention

  The present invention includes many as a process (or method), apparatus, system, composite, computer readable medium, such as a computer readable storage medium, or a computer network in which program instructions are transmitted over an optical or electronic communication link. It can be implemented in an embodiment. In this specification, these implementations or any other form that the invention may take may be referred to as techniques. In general, the order of steps of the disclosed processes may be altered within the scope of the invention.

  A detailed description of one or more aspects of the invention is provided below along with accompanying figures that illustrate the principles of the invention. While the invention will be described with respect to such embodiments, the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous changes, modifications and equivalents. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. These details are given by way of example, and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so as not to unnecessarily obscure the present invention.

  FIG. 1 shows a top view of an article (10) including a display panel (11) embedded in the upper surface of the article (10). A character or graphic design (12) may optionally be represented on the top surface. The term “embedded (or embedded)” in the context of the present invention means that the display panel is integrated into the top surface of the article when attempting to form the article (not after the article has been formed). It is intended to indicate

  Suitable manufacturing processes for forming articles may include, for example, hot stamping (or foil stamping), lamination, injection molding, thermoforming, compression molding or blow molding. Examples of materials suitable for articles in a stamping, lamination or molding process include, but are not limited to: thermoplastic materials such as polystyrene, polyvinyl chloride, acrylics, polysulfone, polyaryl Ester, polypropylene oxide, polyolefin, acrylonitrile-butadiene-styrene copolymer (ABS), methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS), polycarbonate, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyurethane and Other thermoplastic elastomers or mixtures (or blends) etc., as well as thermosetting materials such as reaction injection molding grade polyurethanes, epoxy resins, unsaturated Riesuteru, vinyl esters or complexes thereof, prepreg and mixtures such.

(I) In-mold display transfer film or foil In the manufacture of the article of the present invention, an in-mold display transfer film or foil including a display panel is first prepared.

  Throughout this application, the term “in-mold” is used, but it is understood that the present invention can be extended to processes such as stamping, lamination, or a combination of stamping or lamination and molding processes.

  FIG. 2a is a cross-sectional view of such an in-mold display transfer film or foil (20), which includes a temporary (or temporary) carrier layer (21), a release coating (22), and an optional durable coating (23). A display panel (24) and an adhesive or tie coat layer (25). A release layer (22), a durable layer (23), if present, a display panel (24) and an adhesive layer (25) are sequentially coated or laminated (or laminated) on the carrier film (21). Throughout this application, these different layers will be collectively referred to as an “in-mold display transfer film or foil” for ease of explanation.

  In the in-mold transfer process, an in-mold display transfer film or foil is supplied into the mold such that the temporary carrier layer (21) is in contact with the surface of the mold.

  An important element, the display panel (24), is a particle-based display such as T.W. Flipping ball display as described in SID 02 digest page 119 (2002) by Pham et al; Liquid powder display as described in Hattori et al., SID 03 Digest, page 846 (2003); or electrophoretic display, especially co-pending US patent application Ser. No. 09 / 518,499 (International Publication WO 01 / No. 09 / 879,408 (corresponding to international publication WO 02/100155), US patent application No. 10 / 447,719 (corresponding to international publication WO 03/102673), US patent application No. 10 / 422,413 (corresponding to International Publication WO 03/91798), US Patent Application No. 10 / 422,557 (corresponding to International Publication WO 03/91788), and US Patent Application No. 60 / 375,936. Microcup (registered trademark) EPD as disclosed in There. The disclosures of all cited above are incorporated herein by reference.

  The electrophoretic display may have a traditional (or conventional) up / down switching mode. This is incorporated into co-pending applications US patent application Ser. No. 10 / 198,729 (corresponding to international publication WO 03/009059) and US patent application Ser. No. 10 / 222,036 (corresponding to international publication WO 03/016993), respectively. It may have the disclosed in-plane or dual switching modes, the disclosures of both of which are incorporated herein by reference.

  The display panel can be OLED (organic light emitting device), PLED (polymer light emitting device) or liquid crystal display, especially polymer dispersed liquid crystal (PDLC), microcup (registered). Trademark) LCD (as disclosed in co-pending US patent application Ser. No. 09 / 759,212 (corresponding to WO 02/56097) and US patent application Ser. No. 10 / 178,990, Both of these disclosures may be incorporated herein by reference) or a cholesteric liquid crystal device (ChLCD). A review of reflective displays including PDLC and OLED / PLED can be found in the following books respectively: S. “Liquid Crystal Dispersions” by Drzaic, World Scientific Publishing Co. (1995); “Reflective Liquid Crystal Displays” by Wu and DK, Yang, John Wiley & Sons (2001); and SID 03 digest (2003). All of these disclosures are also incorporated herein by reference.

  The display panel is preferably thin and flexible (or flexible), and the substrate used to form the display can withstand the processing conditions in the transfer process such as injection molding or other molding conditions. Thus, it is preferable to have a high heat deflection temperature. A plastic-based display panel is preferred. The term “plastic-based display panel” in the context of the present invention is a thin film formed on a plastic substrate layer, sandwiched between two plastic substrate layers, or coated with a transparent plastic layer and an insulator. It shall mean a display panel sandwiched between a metal or metal oxide foil or a glass sheet. The metal or metal oxide foil can be formed from carbon steel or stainless steel, Al, Sn, Ni, Cu, Zn, Mg or alloys thereof, oxides, composites or mixtures.

  FIG. 2c is an enlarged view of a plastic-based microcup display panel. The panel (24) has a plurality of display cells (26), an upper electrode plate (27a) and a bottom electrode plate (27b). The display panel can be formed by laminating the top plastic substrate layer (28a) on the bottom plastic substrate layer (28b) or both. Suitable materials for the plastic substrate layer (s) may include the following: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyolefins including polycyclic olefins , Polycarbonate (PC), polymethyl methacrylate (PMMA), polysulfone, polyimide (PI), polyaryl ester, polystyrene, polyurethane, polysiloxane and copolymers, mixtures or composites thereof. PET, PBT, PEN and PC are preferred.

  In a microcup®-based (or microcup-based) display, the display cell (26) is formed from a material selected from the group consisting of thermoplastics, thermoplastic elastomers, thermosets and their precursors. The upper surfaces are individually sealed by the sealing layer.

  In order to obtain a display panel, either the upper electrode layer (27a) side or the bottom electrode layer (27b) side can be the display side. In other words, in an in-mold display transfer film or foil, either the top electrode layer side or the bottom electrode layer side can be brought into contact with the release layer (22) or the durable layer (23) if present during the molding process. .

  In the case of an in-plane switching EPD including an in-plane electrode substrate and an insulator substrate, the display side is preferably the insulator side in order to simplify the connection to the display driver and the external circuit.

  The temporary carrier layer (21) is typically a thin plastic film having a thickness of about 3.5 to about 50 microns. PET, PEN and PC films are particularly preferred because of their low cost, high transparency, and thermomechanical stability.

  In-mold transfer display film release coating (22) allows the display panel coating to be released (or released) from the carrier with minimal damage to the display panel, and a fully automated roll transfer process during molding. realizable.

  Release coatings are typically low surface tension coatings made from materials such as wax, paraffin or silicone, or radiation curable polyfunctional acrylates, silicone acrylates, epoxides, vinyl esters, vinyl ethers, allyl and vinyl, unsaturated polyesters or A highly smooth and impermeable (or impermeable) coating made from materials such as mixtures thereof. The release layer may comprise a condensation polymer, copolymer, mixture or composite selected from the group consisting of epoxy, polyurethane, polyimide, polyamide, melamine formaldehyde, urea formaldehyde and phenol formaldehyde.

  An optional durable coating (23) serves as a protective layer for the display panel (24) and, if present, ink or metal wiring. Suitable ingredients for the durable coating may include, but are not limited to: radiation curable polyfunctional acrylates, including epoxy acrylates, polyurethane acrylates, polyester acrylates, silicone acrylates, glycidyl acrylates, epoxides, vinyl esters, Diallyl phthalate, vinyl ether and mixtures thereof. Optional durable coatings may include condensation polymers or copolymers such as epoxies, polyurethanes, polyamides, polyimides, melamine formaldehyde, urea formaldehyde or phenol formaldehyde. Optional durable coatings can include sol-gel silicates or titanium esters.

  The durable layer of the in-mold transfer display film may be partially or fully cured. When partially cured, a post-curing step will be applied after the molding and / or transfer step to enhance durability, especially hardness, scratch resistance and oil resistance.

In order to improve the release characteristics, it is preferable that the raw material of the durable layer, in particular, low molecular weight components do not penetrate into the release layer. After the durable layer is coated and cured or partially cured, the durable layer becomes slightly compatible or incompatible with the release layer. Binders and additives such as thickeners, surfactants, dispersants, UV stabilizers, or antioxidants are used to control rheology, wettability, coating properties, weather resistance and aging properties. Good. Also, fillers such as silica, Al ₂ O ₃ , TiO ₂ , CaCO ₃ , microcrystalline wax or polyethylene, Teflon (registered trademark) or other lubricating particles may be added to increase the scratch resistance and hardness of the durable layer, for example. You may make it improve. The durable layer is typically about 2 to about 20 microns thick, preferably about 3 to about 8 microns thick. The durable layer in the region covering the display panel is preferably transparent.

  When the durable layer (23) is not present, the upper substrate layer (28a) or the bottom substrate layer (28b) in the display panel (24) can function as a protective layer. In this case, the display substrate layer on the display side may extend beyond the display panel region and cover a part or all of the transfer film or the release film of the foil. The display panel (24) may be laminated directly onto the release layer or the durable layer, if present, optionally with an adhesive layer (not shown).

  In order to properly attach the display panel (24) and, if present, the ink or metal pattern to the top surface of the molded article, an adhesive layer (25) is included in the display panel coating. The adhesive layer may be, for example, polyacrylate, polymethacrylate, polystyrene, polycarbonate, polyurethane, polyester, polyamide, epoxy resin, ethylene vinyl acetate copolymer (EVA) or thermoplastic elastomer, or a copolymer, mixture or composite thereof. It can be formed from materials such as the body. Hot melt or heat activated adhesives such as polyurethane and polyamide are particularly preferred. The thickness of the adhesive layer can be in the range of about 1 to about 20 microns, preferably in the range of about 2 to about 6 microns.

  When a durable layer is present, the printing ink or metal pattern is not present between the display panel (24) and the durable layer (23) or between the durable layer (23) and the adhesive layer (25). May exist in the region. In the absence of a durable layer, a printing ink or metal pattern may be present on the display as described in Section IV below.

(II) In-mold display insertion film or foil FIG. 2b is a schematic cross-sectional view of the in-mold display insertion film or foil. In this case, the carrier layer (21a) becomes part of the final product after stamping, lamination or molding process. The display panel (24) can be laminated with an adhesive layer (not shown) on the carrier film (21a) and optionally the other side can be overcoated with hot melt or heat activated adhesive (25). Alternatively, the display panel can be fabricated directly on the carrier film by methods known in the art, such as those described in co-pending US patent application Ser. No. 09 / 518,488. In this case, the carrier film may include a transparent electrode layer such as indium tin oxide (ITO).

  Similar to the in-mold display transfer film or foil, the printing ink and metal pattern are present in the area where the display is not present, between the display panel and the carrier film, or between the carrier film and the adhesive layer (25). It's okay. Throughout this application, these different layers will be collectively referred to as “in-mold display insert film or foil” for ease of explanation.

(III) Article Manufacture A typical in-mold transfer process is shown in FIG. In this molding process, the in-mold display transfer film or foil is continuously fed into the molding machine in rolls or webs. The mold (30) can be an injection or compression mold for the article (36b). During the molding process, the mold is closed and the article-forming plastic melt is injected (or injected) into the mold cavity (36a) through an injection nozzle and runner. After molding, the display panel, the durable layer, if present, and the ink and metal decorative pattern, if present, are also transferred to the molded article. The molded article is removed from the mold. Further, if the temporary carrier layer (31) and the release layer (32) are also removed at the same time while leaving the durable layer (33), the uppermost layer on the surface of the article is embedded as a part integral with the article. The display panel (34) is provided. Layer (35) is an adhesive layer.

  In order to facilitate alignment of the display transfer film with respect to the mold, alignment marks may be pre-printed on a roll or web, aligned with, for example, an optical sensor, and continuously fed into the mold.

  If the durable layer (33) is not present, one plastic substrate layer of the display panel (34) will be the top layer on the surface of the article.

  In the in-mold insertion process as shown in FIG. 3b, the in-mold display insert film or foil is first cut into appropriate dimensions and shapes and then inserted into the mold (30). The in-mold display insertion film is brought into contact with the mold wall as shown, and is optionally placed under vacuum. The display panel coating can be placed by hand, static electricity may be used to facilitate its insertion, or the insertion may be mechanized. Mechanizing the insert is particularly advantageous for mass production.

  The carrier layer (31a) of the display insertion film is in contact with the inner wall surface of the mold. Thereafter, the mold is closed, and the plastic melt for forming the article (36b) is injected into the mold cavity (36a) through the injection nozzle and the runner. In this case, the carrier film (31a) can be an integral part of the final product. In some cases, the display insertion film may be thermoformed into a predetermined shape or die-cut before being inserted into the mold.

  The mold used for either of the two types of manufacturing processes must be designed with display panel insertion or transfer in mind. To ensure proper thermal transfer through the various layers in the display panel, the gate location must be able to hold the display panel against the mold cavity. Also, the mold must be designed so that the electrodes of the display panel are exposed for connection to the next display driver and external circuitry after molding. In addition, a molding flow and filling analysis should be performed prior to cutting the molding material. Mold cooling analysis should also be considered to minimize molding hot spots. Finally, the presence of a display panel must be considered when setting the molding temperature.

  The connectors that connect the display panel to external circuitry and drivers are not shown in either FIG. 2a or FIG. 2b. The in-mold display transfer film or foil or the in-mold display insertion film or foil may be in the form of a roll.

  FIG. 4a is a cross-sectional view of a rigid article with a display panel embedded in the top surface. Article (40) may have a connection cavity in the body in the form of an open hole or slot (41) as shown so that display panel (42) can be connected to the required circuitry. . The display electrodes (43) are routed through the holes or slots for driver connection and exposed. Attaching an electrical cord (44) or other type of flexible connection harness to an electrode, either with conductive adhesive (45) or mechanical fittings such as ACF, conductive PSA or silver paste Can do.

  FIG. 4b illustrates a snap-in (or snap-in) plug (46) that can be inserted further to secure the coupling area and increase the reliability of the electrode connection. In the direct drive display, the common electrode is arranged on the display side, and in the case of an in-mold display insertion film or foil, the common electrode is applied on the carrier film. The segment electrode of the direct drive display leads to a connection pad arranged on the back surface of the display via a vias (through hole). In the active matrix display, the common electrode is disposed on the display side, and the flexible active switching component layer is disposed on the non-display side. A signal connection pad is located on the back side of the display and communicates with the active switching component via a bias. In passive matrix displays, all row and column electrodes should be routed to the back side to simplify the connection process. Routing can be done via a bias or flexible circuit adapter. In these three types of displays, namely direct drive, active matrix and passive matrix, a display driver (47) can optionally be placed on the display to reduce the number of connection pads and thereby improve the connection quality. And manufacturing costs can be reduced.

  Alternatively, the article can be formed by blow molding or thermoforming to form an inner cavity that houses the circuit. To produce an article by blow molding or thermoforming, the display transfer or insert film is first placed in an open mold and held in place, for example, by vacuum or tension; the mold is then closed. A plastic material for forming an article is thermoformed or blown into a mold. The display panel is attached and embedded on the top surface of a molded article, such as a cup or bottle, similar to an injection or compression molding process.

  Alternatively, the article may be formed by other molding processes such as compression molding, hot stamping or lamination.

(IV) Application of decorative design The design of characters and / or figures may also be represented on the top surface of the article. The most common designs include brand names, logos or symbols or other decorative designs.

  Traditional methods of applying (or applying) decorative designs include screen printing, pad printing, hot stamping, lamination and painting. These methods have historically been post-molding operations that require additional processing steps.

  In recent years, alternative decorative methods such as in-mold foil, insert molding or sublimation thermal transfer have been used. 5 and 6 illustrate the in-mold decoration process.

  FIG. 5 is an enlarged view of the display panel in the in-mold display transfer or insertion film. The display panel comprises a plurality of display cells (50), a top electrode layer (51), a bottom electrode layer (52) and a top plastic substrate layer (53). The decorative design can be screen printed on the first side (54) or the second side (55, back side) of the upper plastic substrate layer. A bottom electrode layer (52) is disposed on the bottom substrate layer (57), and the bottom substrate layer (57) is a plastic molded article (not shown) by an adhesive or bonding (or tie) layer (not shown). Can be combined. The bottom substrate layer is a plastic layer as described above, or a metal or metal oxide foil coated with an insulator, and is carbon steel, stainless steel, Al, Sn, Ni, Cu, Zn, Mg, or an alloy thereof or It may be formed from an oxide.

  FIG. 6 shows the upper substrate with a decorative design on the first surface (64) of the upper plastic substrate layer (63) below the upper durable layer (66) or above the first electrode layer (61) of the display. Fig. 5 shows another embodiment printed on the second side of the layer (63). When the decorative pattern is on the first surface (64), it is highly desirable to have a durable layer (66) above to improve surface hardness, scratch resistance and oil resistance. Similar to the in-mold display film described in FIG. 5, a bottom electrode layer (62) is disposed on the bottom substrate layer (67), and the bottom substrate layer (67) is an adhesive or bonding layer (not shown). ) To a plastic molded article (not shown). The bottom substrate layer is a plastic layer as described above, or a metal or metal oxide foil coated with an insulator, and is carbon steel, stainless steel, Al, Sn, Ni, Cu, Zn, Mg, or an alloy thereof or It may be formed from an oxide.

  The decorative design can also be formed by thermoforming. In this case, the carrier film becomes part of the molded article and the entire decorative layer having a raised or recessed pattern typically has a thickness in the range of about 0.2 to about 1 mm, preferably about 0.3 to It is in the range of about 0.7 mm. This is usually obtained by thermoforming ABS, polystyrene or PVC sheets in a mold.

  Alternatively, the decorative layer can also be formed by high pressure molding including using high pressure air to form a decorative design on the film. In addition, the decorative layer can be formed not by air but by hydroforming in which a hydrostatic bladder functions as a formation mechanism.

  It should also be noted that the decorative layer made from any one of the methods described above should have a decorative design that is strategically printed in an area that does not overlap the display panel. In other words, the decorative design should not interfere with the display image (or display image).

  Although the invention has been described with reference to particular embodiments of the invention, it will be understood that various modifications can be made and replaced with equivalents without departing from the true concept and scope of the invention. . In addition, many modifications can be made to adapt to a particular situation. All such modifications are intended to be within the scope of the present invention.

  Although the above embodiments have been described in some detail for purposes of clarity of understanding, the present invention is not limited to such details. There are many alternative ways of implementing the invention. The disclosed aspects are exemplary and not restrictive.

FIG. 2 shows a top view of the article of the present invention. It is sectional drawing of the in-mold transfer film or foil containing a display panel. It is sectional drawing of the in-mold insertion film | membrane or foil containing a display panel. 1 is an enlarged view of a typical plastic-based display panel. FIG. It is sectional drawing of the injection molding process using an in-mold transfer film or foil. It is sectional drawing of the injection molding process using an in-mold insertion film or foil. 1 illustrates an article of the present invention having an inner cavity. 1 illustrates an article of the present invention having an inner cavity. 1 illustrates the application of a decorative design to an article of the present invention. 1 illustrates the application of a decorative design to an article of the present invention.

Claims (68)

  A plastic article having a display panel embedded in an upper surface.   The article of claim 1, wherein the display panel is seamlessly coupled to a non-display portion of the article.   The article of claim 1 formed by molding, stamping, lamination, or a combination thereof.   4. An article according to claim 3, wherein the molding process is injection molding, compression molding, thermoforming or blow molding.   The article of claim 1, wherein the display panel is in intimate contact with a top surface of the article.   The article of claim 1, wherein the upper display substrate layer of the display panel is the same as the upper layer of the article.   The article of claim 1 formed from a material selected from the group consisting of thermoplastic materials, thermoplastic elastomers, thermosetting materials and mixtures thereof, prepregs or composites.   The thermoplastic material is polystyrene, polyvinyl chloride, acrylic resin, polysulfone, polyaryl ester, polypropylene oxide, polyolefin, acrylonitrile-butadiene-styrene copolymer (ABS), methacrylate-acrylonitrile-butadiene-styrene copolymer (MABS). The article of claim 7, wherein the article is polycarbonate, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyurethane or composites, prepregs or mixtures thereof.   8. The article of claim 7, wherein the thermosetting material is a reaction injection molding grade polyurethane, epoxy resin, unsaturated polyester, vinyl ester or composite, prepreg or mixture thereof.   The article of claim 1, wherein the display panel is an electrophoretic display, a flipping ball display, a liquid powder display, or other particle type display.   The article of claim 10, wherein the electrophoretic display is Microcup® based.   The article of claim 1, wherein the display panel is a liquid crystal display.   The article of claim 12, wherein the liquid crystal display is Microcup®-based.   The article of claim 10, wherein the electrophoretic display has a traditional up / down, in-plane or dual switching mode.   The article of claim 1, wherein the display panel is an OLED or a PLED.   The article of claim 12, wherein the liquid crystal display is a polymer dispersed liquid crystal or cholesteric liquid crystal display.   The display panel is formed on a plastic substrate layer and sandwiched between two plastic substrate layers, or sandwiched between a transparent plastic layer and a thin metal or metal oxide foil or glass sheet. The article according to 1.   The plastic substrate layer is made of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyolefin, polycarbonate (PC), polymethyl methacrylate (PMMA), polysulfone, polyimide (PI), polyaryl ester The article of claim 17, formed from polystyrene, polyurethane, polysiloxane or copolymers, mixtures or composites thereof.   The article of claim 17, wherein the plastic substrate material is formed from PET, PBT, PEN or PC.   The article of claim 17, wherein the metal or metal oxide foil is formed from steel, Al, Sn, Ni, Cu, Zn, Mg, or alloys, oxides, composites or mixtures thereof.   21. The article of claim 20, wherein the steel is carbon steel or stainless steel.   The article of claim 1, further comprising a decorative design on an upper surface thereof.   23. The article of claim 22, wherein the decorative design is applied by post-molding.   23. The article of claim 22, wherein the decorative design is applied by an in-mold process.   23. The article of claim 22, wherein the display panel includes a plurality of display cells sandwiched between an upper display side flexible substrate layer and a bottom flexible substrate layer.   The article according to claim 25, wherein the upper display side flexible base material layer is a transparent base material layer.   27. The article of claim 26, wherein the upper display side flexible substrate layer is a transparent plastic substrate layer.   26. The article of claim 25, wherein the bottom flexible substrate layer is a plastic substrate layer, a thin metal or metal oxide foil or a glass sheet.   26. The article of claim 25, wherein the decorative design is represented on one side of the upper display side substrate layer.   23. The article of claim 22, wherein the display panel has a decorative design in a non-display area.   23. The article of claim 22, wherein the decorative design is formed on the article by injection molding, compression molding, thermoforming, blow molding, hot stamping, lamination, or combinations thereof.   The article of claim 1 which is a plastic cover for a mobile phone or pager.   33. The article of claim 32, wherein the display panel is microcup based.   The article according to claim 1, which is a personal item.   The article of claim 1, wherein the article is a toy or an educational device.   The article according to claim 1, which is a plastic cover of a portable information terminal or an electronic book.   The article of claim 1, wherein the article is a credit or smart card or an identification card or business card.   The article of claim 1, wherein the article is an album, watch, wall clock or table clock, radio or camera face.   The article of claim 1, which is an automobile dashboard.   The article of claim 1 which is a household product.   The article according to claim 1, which is a housing of a laptop computer, a carrying case of a consumer electronic device or a front control panel.   An in-mold display transfer film or foil comprising a temporary carrier film, a release layer, a display panel, and an adhesive or tie layer and optionally a durable layer.   An in-mold display transfer film or foil further comprising an adhesive layer between the display panel and the release layer.   43. The in-mold display transfer film or foil of claim 42, wherein the temporary carrier layer is a thin film of PET, PEN or PC.   The release layer is made of wax, paraffin or silicone, or radiation curable polyfunctional acrylate, silicone acrylate, epoxide, vinyl ester, vinyl ether, allyl or vinyl, unsaturated polyester or mixtures thereof, and is highly smooth and impermeable 43. The in-mold display transfer film or foil of claim 42 formed from a coating of:   43. The in-mold of claim 42, wherein the release layer comprises a condensation polymer, copolymer, mixture or composite selected from the group consisting of epoxy, polyurethane, polyimide, polyamide, melamine formaldehyde, urea formaldehyde and phenol formaldehyde. Display transfer film or foil.   43. The in-mold display transfer film or foil of claim 42, wherein the optional durable coating is formed from a radiation curable multifunctional acrylate, epoxide, vinyl ester, diallyl phthalate, vinyl ether or mixtures thereof.   43. The in-mold display transfer film or foil of claim 42, wherein the optional durable coating comprises a condensation polymer or copolymer.   49. The in-mold display transfer film or foil of claim 48, wherein the condensation polymer or copolymer is selected from the group consisting of epoxy, polyurethane, polyamide, polyimide, melamine formaldehyde, urea formaldehyde, and phenol formaldehyde.   43. The in-mold display transfer film or foil of claim 42, wherein the optional durable coating comprises sol-gel silicate or titanium ester.   48. The in-mold display transfer film or foil of claim 47, wherein the radiation curable polyfunctional acrylate is epoxy acrylate, polyurethane acrylate, polyester acrylate, silicone acrylate or glycidyl acrylate.   The adhesive layer is formed from polyacrylate, polymethacrylate, polystyrene, polycarbonate, polyurethane, polyester, polyamide, epoxy resin, ethylene vinyl acetate copolymer (EVA) or thermoplastic elastomer, or a copolymer, mixture or composite thereof. 43. The in-mold display transfer film or foil of claim 42.   43. The in-mold display transfer film or foil according to claim 42, wherein the adhesive layer is a hot melt or a heat activated adhesive.   43. The in-mold display transfer film or foil according to claim 42, wherein the adhesive layer is polyurethane, polyamide, or a copolymer, mixture or composite thereof.   43. The in-mold display transfer film or foil of claim 42, wherein the adhesive layer is polycarbonate, polyacrylate, polymethacrylate or copolymers, mixtures or composites thereof.   43. The in-mold display transfer film or foil of claim 42, having a roll form.   An in-mold display insert film or foil comprising a carrier layer, a display panel and an adhesive layer.   58. The in-mold display insert film or foil of claim 57, wherein the display panel is formed directly on a carrier layer.   58. The in-mold display insert film or foil of claim 57 having the form of a roll. A method of manufacturing an article having a display panel embedded in an upper surface of the article, comprising:
a) forming an in-mold display transfer film or foil comprising a temporary carrier layer, a release layer, a display panel, an adhesive layer and optionally a durable layer;
b) supplying the in-mold display transfer film or foil into the mold such that the temporary carrier film is in contact with the inner surface of the mold;
c) injecting plastic material into the mold to form the article;
d) removing the formed article from the mold; and e) removing both the temporary carrier layer and the release layer simultaneously. A method of manufacturing an article having a display panel embedded in an upper surface of the article, comprising:
a) forming an in-mold display insert film or foil comprising a carrier layer, a display panel and an adhesive layer;
b) supplying the in-mold display insert film or foil into the mold such that the carrier layer is in contact with the inner surface of the mold;
c) injecting plastic material into the mold to form the article;
d) A method comprising removing the formed article from the mold.   64. The method of claim 61, wherein the display panel is formed directly on a carrier layer. A method of manufacturing an article having a display panel embedded in an upper surface of the article, comprising:
a) forming an in-mold display transfer film or foil comprising a temporary carrier layer, a release layer, a display panel, an adhesive layer and optionally a durable layer;
b) supplying the in-mold display transfer film or foil into the mold such that the temporary carrier film is in contact with the inner surface of the mold;
c) thermoforming or blow molding the article with a plastic material in a mold;
d) removing the formed article from the mold; and e) removing both the temporary carrier layer and the release layer simultaneously. A method of manufacturing an article having a display panel embedded in an upper surface of the article, comprising:
a) forming an in-mold display insert film or foil comprising a carrier layer, a display panel and an adhesive layer;
b) supplying the in-mold display insert film or foil into the mold such that the carrier layer is in contact with the inner surface of the mold;
c) thermoforming or blow molding the article with a plastic material in a mold;
d) A method comprising removing the formed article from the mold.   The method of claim 64, wherein the display panel is formed directly on the carrier film. A method of manufacturing an article having a display panel embedded in the top surface of the article, comprising:
a) forming an in-mold display transfer film or foil comprising a temporary carrier layer, a release layer, a display panel, an adhesive layer and optionally a durable layer;
b) supplying the in-mold display transfer film or foil into the mold such that the temporary carrier film is in contact with the inner surface of the mold;
c) compression molding the article with a plastic material in a mold;
d) removing the formed article from the mold; and e) removing both the temporary carrier layer and the release layer simultaneously. A method of manufacturing an article having a display panel embedded in an upper surface of the article, comprising:
a) forming an in-mold display insert film or foil comprising a carrier layer, a display panel and an adhesive layer;
b) supplying the in-mold display insert film or foil into the mold such that the carrier layer is in contact with the inner surface of the mold;
c) compressing the article with a plastic material in a mold; and d) removing the formed article from the mold. 68. The method of claim 67, wherein the display panel is formed directly on the carrier film.

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