NL2005498C2 - Display as well as method and apparatus for manufacturing a display. - Google Patents

Display as well as method and apparatus for manufacturing a display. Download PDF

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Publication number
NL2005498C2
NL2005498C2 NL2005498A NL2005498A NL2005498C2 NL 2005498 C2 NL2005498 C2 NL 2005498C2 NL 2005498 A NL2005498 A NL 2005498A NL 2005498 A NL2005498 A NL 2005498A NL 2005498 C2 NL2005498 C2 NL 2005498C2
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NL
Netherlands
Prior art keywords
layer
color filter
image display
filter layer
display
Prior art date
Application number
NL2005498A
Other languages
Dutch (nl)
Inventor
Michel Josephus Marie Somers
Fredericus Johannes Touwslager
Nicolaas Aldegonda Jan Maria Aerle
Original Assignee
Polymer Vision Bv
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Filing date
Publication date
Application filed by Polymer Vision Bv filed Critical Polymer Vision Bv
Priority to NL2005498A priority Critical patent/NL2005498C2/en
Application granted granted Critical
Publication of NL2005498C2 publication Critical patent/NL2005498C2/en

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133509—Filters, e.g. light shielding masks
    • G02F1/133514—Colour filters
    • G02F1/133516—Methods for their manufacture, e.g. printing, electro-deposition or photolithography
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/165—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on translational movement of particles in a fluid under the influence of an applied field
    • G02F1/166—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on translational movement of particles in a fluid under the influence of an applied field characterised by the electro-optical or magneto-optical effect
    • G02F1/167—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on translational movement of particles in a fluid under the influence of an applied field characterised by the electro-optical or magneto-optical effect by electrophoresis
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/165—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on translational movement of particles in a fluid under the influence of an applied field
    • G02F1/1675—Constructional details
    • G02F1/1677—Structural association of cells with optical devices, e.g. reflectors or illuminating devices
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F2202/00—Materials and properties
    • G02F2202/28—Adhesive materials or arrangements

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  • Physics & Mathematics (AREA)
  • Nonlinear Science (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Mathematical Physics (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Molecular Biology (AREA)
  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)

Description

Display as well as method and apparatus for manufacturing a display
BACKGROUND
5 Field of the invention
The present invention relates to a display.
The present invention further relates to a method for manufacturing a display.
The present invention further relates to an apparatus for manufacturing a display.
10
Background of the invention
Multi color displays are known that have a display effect layer capable of generating a pattern by reflecting, transmitting or emitting light with a broad color spectrum (white) and a color filter layer that is capable to convert said light into colored light. 15 One such display is known from W02007/063440.
FIG. 1 schematically shows a typical conventional display for displaying a color image. The display comprises a substrate 2, a display layer 4 and a color filter layer 6. The display layer is typically composed of a stack of sub-layers, including a bottom electrode layer 42, a display effect layer 44 and a top electrode layer 46. The 20 bottom electrode 42 may comprise a plurality of electrode elements (not shown) that may be controlled by corresponding control elements in an active matrix layer. The top electrode 46 typically is a continuous, transparent electrode. The display layer 44 comprises display elements 440 having an optical property that is controlled by the electrodes 42, 46. In this embodiment the display elements 440 are electrophoretic 25 elements formed by capsules with a dispersion of electrically charged black and white or colored nano-particles in a clear solution. Each picture element (pixel), i.e. independently controlled unit of the display, may comprise one or more display elements 440. The display elements need not necessarily be aligned with the pixel boundaries. The display layer 4 is constructed to display an image having at least a 30 luminosity component and the color filter layer 6 comprises a color filter with a plurality of color filter elements 64 (red), 66 (green), 68 (blue) for filtering the image according to a predetermined pattern. The color filter layer 6 further comprises transparent colorless elements 62. The color filter layer 6 may be implemented in 2 various ways. In the example of FIG. 2A, each pixel has 4 sub-pixels that are arranged in 4 quadrants of a rectangle. Therein sub-pixel 2a includes a display element that corresponds to a color-less filter element, and sub-pixels 2b, 2c and 2d respectively include a display element that respectively corresponds to a red, green 5 and blue color filter element. In the example of FIG. 2B, each pixel comprises three elongate sub-pixels la, lb, lc that are arranged lengthwise along each other. FIG.
2C shows a third example wherein three square subpixels 3a, 3b, 3c of each primary color are arranged within a T-shaped pixel.
The application of the color filter 6 requires additional manufacturing steps.
10 If these steps are not successful the quality of the product may be low, or the product may even be unsuitable for use. Various causes may result in a failure of the additional manufacturing steps, such as the presence of particles, malfunctioning of the equipment, human errors. There is a need to at least mitigate these advantages caused by failure introduced during the additional manufacturing steps.
15
SUMMARY
According to a first aspect of the present invention a display as claimed in claim 1 is provided.
20 According to a second aspect of the present invention a method according to claim 2 is provided.
According to a third aspect of the present invention an apparatus according to claim 10 is provided.
The display according to the first aspect of the invention has a removably 25 attached color filter. Accordingly, if it is determined that the display does not comply with the requirements due to a failure introduced during the additional manufacturing steps, it is possible to remove the color filter layer. Therewith a compliant monochrome or black and white display is obtained. Alternatively, a new attempt may be made to apply a color filter layer to the display layer.
30 The method according to the second aspect of the invention is characterized by removably attaching the color filter layer to the display layer. Accordingly, if after carrying out the additional manufacturing steps it is recognized that the manufactured product does not comply with the requirements for a color display, it 3 is possible to remove the color filter and use the product as a monochrome or a black and white display.
The apparatus according to the third aspect of the invention is characterized by third unit for removably attaching the color filter layer to the display layer.
5 Accordingly, if after carrying out the additional manufacturing steps it is recognized that the manufactured product does not comply with the requirements for a color display, it is possible to remove the color filter and use the product as a monochrome or a black and white display.
The wording “removably attached” is understood to mean that the color filter 10 layer can be removed from the display layer without damaging the display layer. Nevertheless the color filter layer should be sufficiently tightly attached to the display layer to prevent a spontaneous release thereof during normal use of the device.
As used herein, a "layer" of a given material includes a region of that 15 material whose thickness is small compared to both its length and width. Examples of layers include sheets, foils, films, laminations, coatings, and so forth. As used herein a layer need not be planar, but can be bent, folded or otherwise contoured, for example, to at least partially envelop another component. As used herein a layer can also include multiple sub-layers. A layer can also consist of a collection of discrete 20 portions, for example, a layer of discrete active regions comprising individual pixels.
Accordingly an embodiment of the method according to the second aspect further comprises a step of testing the display after the step of removably attaching the color filter layer and a step of removing the color filter layer from the display layer if the display does not positively pass this test. The resulting display layer may 25 be used in a monochromatic display, or a new attempt may be made to provide the display layer with a color filter layer. Hence in the method according to the second aspect of the invention, the materials and efforts spent in the previous manufacturing steps are not lost if the test indicates that the color filter layer is not correctly attached to the display layer.
30 Likewise an embodiment apparatus according to the third aspect of the invention comprises 4 a fourth unit for testing a quality of the product obtained by removably attaching the color filter layer to the display layer, and for providing a failure signal if the quality of the product is not acceptable, and a fifth unit for removing the color filter layer from the display layer upon 5 activation of the failure signal.
Alternatively, the fourth and the fifth unit may be provided as a separate apparatus.
Various options are possible to removably apply the color filter layer and to remove the color filter layer in case it is detected that the additional manufacturing 10 steps did not result in an acceptable color display.
According to a first option the color filter layer is removably attached to the display layer by an intermediate adhesion layer having a relatively low adherence to the display layer as compared to the adhesion to the color filter layer and the step of removing the color filter layer from the display layer if the display does not 15 positively pass this test is carried out by peeling of the color filter layer from the display layer. Release of the color filter layer with the adhesion layer may be promoted by a temperature increase.
According to a second option the color filter layer comprises a release layer at a surface attached to the display layer and the step of removing the color filter layer 20 from the display layer if the display does not positively pass this test is carried out by peeling of the color filter layer from the display layer.
According to a third option the color filter layer is attached to the display layer by means of an intermediate layer that is soluble in a solvent that does not solve the display layer and the step of removing the color filter layer from the 25 display layer if the display does not positively pass this test is carried out by selectively solving the intermediate layer in a solvent.
According to a fourth option the color filter layer is soluble in a solvent that does not solve the display layer and the step of removing the color filter layer from the display layer if the display does not positively pass this test is carried out by 30 selectively solving the color filter layer in a solvent. This is advantageous in that an intermediate layer is superfluous.
An embodiment of the method according to the second aspect of the invention further comprises the step of testing the provided display layer and the step of 5 removably attaching the color filter layer is only carried out after the provided display layer has positively passed the step of testing. In this way the step of removably attaching the color filter is avoided if it is known beforehand that the manufacturing process will not result in an acceptable display anyhow.
5 If the method according to the second aspect of the invention is successfully completed, a display according to the first aspect of the invention is obtained that comprises a display layer for displaying an image having at least a luminosity component and a color filter layer releasable attached thereto that comprises a color filter for filtering the image according to a predetermined pattern.
10
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects are described in more detail with reference to the drawings wherein: 15 FIG. 1 shows a prior art display unit having a display layer and a color filter layer, FIG. 2 shows known arrangements of a color filter layer, FIG. 3 shows a first embodiment of a display unit according to the first aspect of the present invention, 20 FIG. 4 shows an embodiment of a method according to the second aspect of the invention, FIG. 4A to 4D further illustrates various steps in the embodiment of the method of FIG. 4, therein FIG. 4A further illustrates a first step Si of the method, 25 FIG. 4B further illustrates a second step S2 of the method, FIG. 4C further illustrates a first sub-step S5A of a fifth step S5 of the method, FIG. 4D further illustrates a second sub-step S5B of the fifth step S5 of the method, 30 FIG. 5A shows an embodiment of an apparatus according to the third aspect of the invention in a first operational state, FIG. 5B shows the embodiment of the apparatus according to the third aspect of the invention in a second operational state, 6 FIG. 6A schematically shows an alternative embodiment of the apparatus according to the third aspect of the invention, FIG. 6B shows a part of the apparatus of FIG. 6 in more detail, FIG. 6C schematically shows another alternative embodiment of the 5 apparatus according to the third aspect of the invention, FIG. 7 illustrates a first sub-step S5A carried out by said part in more detail, FIG. 8 illustrates a second sub-step S5B carried out by said part in more detail.
10
DETAILED DESCRIPTION OF EMBODIMENTS
In the following detailed description numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will 15 be understood by one skilled in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to obscure aspects of the present invention.
Embodiments of the invention are described herein with reference to cross-20 section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the invention should not be construed as limited to the particular shapes and sizes of regions illustrated herein but are to 25 include deviations in shapes that result, for example, from manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as 30 having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
7
It will be understood that when an element or layer is referred to as being "coupled to" another element or layer, it can be directly on, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "connected to" another element or 5 layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
FIG. 3 shows a first embodiment of a display according to the first aspect of the present invention. The display therein comprises a substrate 2. In the 10 embodiment shown the substrate is a polymer foil, such as a PET (Poly Ethylene
Terephthalate) or PEN (Poly Ethylene Naphthalate) layer having a thickness of less than 50pm, preferably about 25pm. Alternatively a metal foil may be used as the substrate. It is not necessary that the substrate is flexible. In an alternative embodiment a rigid substrate, e.g. a glass plate, may be used. The substrate 2 15 carries a display layer 4 that comprises a display effect layer 44 arranged between a backplane 42 with an active matrix layer and electrode elements and a transparent electrode layer 46. The display effect layer 44 comprises a plurality of display elements 440, here electrophoretic elements. Alternatively other display elements, e.g. liquid crystal elements, or (O)LEDs may be used as the display elements. The 20 display further comprises a color filter layer 6 that is removably attached to the display layer 4. The structure of the color filter 6 can be matched to the type of display elements used. For example for use in combination with electrophoretic elements as the display elements the color filter may comprise colorless transparent spacings 62, whereas for use in combination with liquid crystal display elements the 25 color filter elements 64 (red), 66 (green), 68 (blue) may even overlap for example.
The removable attachment of the color filter layer 6 to the display effect layer 4 makes it possible to remove the color filter layer 6 from the display effect layer 4 if it is found out that the color filter layer 6 was not properly attached to the display effect layer 4. In the embodiment shown the color filter layer 6 is removably 30 attached to the display layer by an intermediate weak adhesion layer 8. In practice an intermediate substrate 48 may be present between the adhesion layer 8 and the common electrode 46. The material used for the intermediate substrate is typically a 8 polymer, e.g. PET or PEN. The intermediate substrate may have a thickness in the order of a few micrometer to a few tens of micrometer, e.g. 12.5 micrometer. The term “weak adhesion” is understood to mean that the peeling force for releasing the layer 8 from at least one of the color filter layer 6 and the display effect layer 4 is 5 preferably at most 3.2 g/mm at room temperature (20 °C). Nevertheless, the peeling is preferably at least 0.8 g/mm so that a spontaneous separation of the color filter layer 6 from the display effect layer 4 is prevented. Nevertheless, an adhesion layer may be used having a temperature dependent adhesion. For example an adhesion layer may be used having an adhesion decreasing with temperature. In that case the 10 peeling strength at room temperature may be higher than 3.2 g/mm, e.g. 10 g/mm.
In an embodiment the adhesion layer 8 has a relatively low adherence to the display layer 4 as compared to the adhesion to the color filter layer 6. In that case the color filter layer 6 can be removed together with the adhesive layer 8 from the display layer 4.
15 In the embodiment shown the adhesive is an EVA adhesive (ethylene vinyl acetate). Other suitable adhesives are (urethane)acrylics.
FIG. 4 schematically shows a method for manufacturing a display according to the second aspect of the present invention.
The method comprises a first step Si of providing a display layer as shown in 20 FIG. 4A for displaying an image having at least a luminosity component. Various ways are known to manufacture a display layer and for clarity these will not be described in detail here.
In a second step S2 a color filter layer comprising a color filter for filtering the image according to a predetermined pattern is provided, as is shown in FIG. 4B. 25 Also the color filter layer is manufactured in a way known as such to the skilled person. In a practical embodiment the color filter layer is directly processed upon the display layer. Said processing may involve for example a step of spinning and lithographic treatment for each of the color filter layers. Alternatively the color filter layer may be manufactured separately and be subsequently laminated upon the 30 display layer.
In a third step S3 the display layer is tested. During this test it is determined whether the display layer correctly functions. If it is determined that the display 9 layer does not comply with the requirements (NOK) the display layer is rejected in step S4 before attaching the color filter layer, so that the latter can be used for another product.
If it is determined that the display layer does comply with the requirements 5 (OK) then in step S5 the color filter layer is attached removably to the display layer.
As shown in FIG. 4C, step S5 comprises a first sub-step S5A of applying an adhesive to a surface of the display layer at a side that is to be provided with the color filter layer. The adhesive may be applied for example by a printing process.
The adhesive, e.g. EVA may be heated to reduce the viscosity, therewith facilitating 10 the printing process. In an embodiment of the method the display layer may already be prepared with a removably attached intermediate substrate. This embodiment can be implemented very cost-effective in a roll to roll method.
In a second sub-step S5B, as shown in FIG. 4D, the color filter layer is laminated to the surface of the display layer 4 provided with the adhesive layer 8.
15 Therewith the product of FIG. 3 is obtained.
In a subsequent step S6, the product so obtained is tested. The test may comprise application of test signals to the display manufactured in steps Si, S2, S3 and S5 and to determine whether the generated color image corresponds to a reference image.
20 If it is determined in step S6 that the product passes the test (OK), the manufacturing processes for the product, e.g. integration with other components may be continued if necessary and the product may be packaged. Alternatively the so obtained display may be sold as a semi-finished product.
If it is determined in step S6 that the product does not pass the test (NOK), 25 then the color filter layer is removed from the display layer in step S8.
With this step S8 it is achieved that the malfunctioning color display becomes a well functioning black and white or monochrome display. The so obtained black and white or monochrome display may be further processed in step S9, e.g. by integration with other components and packaging. Alternatively the so obtained 30 display may be sold as a semi-finished product. According to yet another alternative step S5 may be repeated, involving application of a new removable intermediate substrate at the display layer and application of a new color filter at the new intermediate substrate.
10 FIG. 5A, 5B illustrates an apparatus for manufacturing a product according to the third aspect of the present invention. The apparatus comprises a first unit 110 for providing a display layer 4. The display layer is arranged for displaying an image having at least a luminosity component. In the embodiment shown the first unit 110 5 is a supply roll that supplies the display layer 4 laminated on a substrate as shown in FIG. 4A.
The apparatus comprises a second unit 120 for providing a color filter layer for filtering the image according to a predetermined pattern
The apparatus comprises a lamination unit 130 for removably attaching the 10 color filter layer 6 to the display layer 4. The lamination unit 130 comprises an applicator 132, for example a printer for applying an adhesive layer at a surface of the display layer 4 to be provided with the color filter layer and further comprises a pair of lamination rolls 134, 136. In FIG. 5A, 5B reference numeral 7 denotes the laminated product comprising the display layer 4 and the color filter layer 6.
15 The apparatus comprises a third unit 140 for testing a quality of the product having the removably attached color filter layer on the display layer. In this embodiment the third unit comprises a camera 142 and a controller 144. The camera 142 provides an image of the product to the controller 144. The controller 144 verifies whether the display layer 4 and the color filter layer 6 are properly aligned, 20 for example by determining a relative position of alignment marks present in the display layer and the color filter layer. In a further test a yield is determined. For example it may be determined whether color elements in the color filter layer are missing or incomplete. If the display layer 4 and the color filter layer 6 are not properly aligned, or the product would otherwise have an unacceptable low quality, a 25 failure signal Err is provided.
The apparatus comprises a fourth unit 150 for removing the color filter layer 6 from the display layer 4 upon activation of the failure signal Err.
The fourth unit 150 comprises a first and a second roll 152, 154 having a perforated outer surface. In the absence of the failure signal Err the first and the 30 second roll 152, 154 guide the laminated product 7 towards further guidance means, here indicated by a guidance roll 160.
In the case the failure signal Err is activated, a vacuum pump 151 is switched on that evacuates the interior of the first and a second roll 152, 154. The 11 pressure difference between the environment and the surface of the rolls causes the display layer 4 and the color filter layer 6 to be torn apart. The display layer 4 is carried away by the first roll 152 and the color filter layer 6 is carried away by the second roll 154. After a sufficient part of the display layer 4 and the color filter layer 5 6 are separated from each other, these parts may be separated from their respective remainders e.g. by cutting, e.g. by laser cutting. After separation the pressure inside the rolls 154, 156 may be restored so that the disconnected parts 4a, 6a drop onto respective transport facilities 156 and 158, as indicated by dotted lines.
FIGs. 6A and 6B schematically show a first and a second alternative 10 embodiment of an apparatus for manufacturing a display. The apparatuses of FIG. 6A, 6B differs from the apparatus of FIG. 5A, 5B in that the product is manufactured piecewise contrary to the apparatus of FIG. 5A, 5B that manufactures the products in a roll to roll process.
The apparatus of FIG. 6A comprises a first unit 110 for providing a display 15 layer. The said display layer is arranged for displaying an image having at least a luminosity component. In practice the manufacturing of a display layer requires a plurality of modules for executing a plurality of manufacturing steps. It is however well known to the skilled person how to implement these steps and the required equipment, so that these aspects are not described in detail here in order not to 20 obscure the description of the present invention. The apparatus of FIG. 6A further has a second unit 120 for providing a color filter layer for filtering the image according to a predetermined pattern. Likewise the second unit 120 is not shown in detail. The display layer 4 provided by the first unit 110 is transported by a transport facility 171 to a first test station 114. In this test station 114 line- and 25 pixelfaults are determined. In the test station 114 a display layer that does not comply with the requirements is carried away by transport away 173. Compliant display layers are transported by transport facility 174 to a second unit 120, wherein a color filter layer 6 is applied to the display layer 4. Although for clarity the second unit 120 is shown as a single block, this unit will in practice comprise a plurality of 30 modules. In a first module for example an intermediate substrate is attached at a surface of the display layer 4 remote from the substrate 2. In a second module of the second unit a color filter layer is applied. In an embodiment of the second module color filter elements for respective primary colors are applied at the intermediate 12 substrate. For each of the primary colors, this involves for example a spin coating step, followed by a lithographic step. .
FIG. 6B shows the second unit 120 in more detail. As shown therein the second unit 120 comprises a first module 121 wherein a colorfilter resist layer 8a is 5 applied at a side of the display layer 4 that is to be provided with the color filter layer. In an embodiment the color resist layer is applied by spinning a color resist material at said side of the display layer 4. Nevertheless the color resist material may also be applied by other methods, e.g. by printing. The color resist layer 8a, may for example may be a commercially available photo-resist materials, preferably low 10 process temperature, not higher than about 80 to 90°C. Suitable materials for this purpose are for example the ’’color mosaic” series, available from Fujifilm. The semifinished product so obtained, as shown in FIG. 7 is then transported to a second module 123 wherein the color resist layer 8a is cured, e.g. by a application of UV-radiation. Modules 121 and 123 carry out step S5A of an embodiment of the method 15 described with reference to FIG. 4, resulting in the semi-finished product of FIG. 8.
The semi-finished product having the color filter layer 6 removably attached to the display layer 4 is then transported by transport facility 177 to testfacility 124.
Test facility 124 verifies whether the semi-finished product complies with predetermined test requirements, e.g. whether the color filter layer 6 is properly 20 aligned with the display layer and/or whether the color filter layer is complete i.e. whether no color filter elements are missing. In the test facility it may also be verified whether the product is free from dust particles encapsulated between the display layer and the color filter layer. This corresponds to step S6 of the method. The testfacility 124 generates a signal Err having a value dependent on the outcome 25 of the test generates a test signal Err. The tested semi-finished product is transported by transport facility 178 to a distribution unit 145. If the test signal Err indicates that the semi-finished product does not comply with the requirements the distribution facility transports the semi-finished product by transport facility 179 to the fourth unit 150 for removing the color filter layer 6 from the display layer 4. The 30 fourth unit 150 comprises a facility that removes the intermediate substrate carrying the color filter from the display layer. Therewith the color filter layer 6 is released from the display layer 4. This corresponds to step S8 of the method. Then 13 the display layer 4 from which the color filter layer 6 is removed is then further transported by transport facility 181 for further handling as a monochrome or a black and white display unit, corresponding to step S9. For example it may be packaged by a packaging unit 155. It is alternatively possible that the display layer 5 4 of which the color filter layer 6 was released is fed back to the second unit 120 by a transport facility 182 to attempt to apply a new color filter layer. In case the test signal Err indicates that the semi-finished product complies with the requirements the distribution facility 145 passes the semi-finished product to the transport facility 180 for further handling as a color display unit. The semi-finished product may for 10 example be transported to a package unit 160. Transport and further handling correspond to step S7 of the method described with reference to FIG. 4.
FIG. 6C shows an alternative embodiment of a manufacturing apparatus. Parts thereof corresponding to those in FIG. 6A have the same reference number. In the apparatus of FIG. 6C, the color filter layer is manufactured in a separate process 15 by second unit 120. The so obtained color filter is then transported by transport facility 172 to a test facility 126 that separately tests the color filter for missing or incomplete color filter elements. If this test points out that the color filter does not comply with the requirements, it is transported away by transport facility 175. If the test points out that the color filter does comply with the requirements, the color 20 filter is transported by transport facility 176 to a lamination station 130, where it is laminated with the display layer. The laminated product obtained from lamination station 120 is then transported by transport facility 177 to a further test station 140, where it is verified whether the color filter layer and the display layer are mutually correctly aligned, and whether no air bubbles or dust are enclosed between the 25 layers. Dependent on the outcome of the test, the laminated product is then further processed in a way similar to that described with reference to FIG. 6A.
For obtaining a high accuracy of alignment, e.g. more than 10pm between the display layer and the color filter layer the method described with reference to FIG. 6A is preferred. Therein preferably the product to be manufactured is processed on a 30 substrate that is laminated on a rigid carrier such as silica or glass. After completion the product may be released from the carrier. In case a high accuracy is not necessary a lamination apparatus as described with reference to FIG. 6C may be used.
14
In the claims the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single component or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different claims does not 5 indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.

Claims (14)

1. Beeldscherm omvattende een beeldweergavelaag (4) voor het weergeven van een beeld met tenminste een helderheidscomponent en een kleurfilterlaag (6) die 5 losneembaar is bevestigd aan de beeldweergavelaag en die een kleurfilter omvat voor het filteren van het beeld volgens een van te voren bepaald patroon.A display comprising an image display layer (4) for displaying an image with at least one brightness component and a color filter layer (6) detachably attached to the image display layer and comprising a color filter for filtering the image according to a predetermined pattern. 2. Werkwijze voor het vervaardigen van een beeldscherm, omvattende de stappen van 10 het verschaffen (Sl) van een beeldweergavelaag voor het weergeven van een beeld met tenminste een helderheidscomponent, het verschaffen (S2) van een kleurfilterlaag omvattende een kleurfilter voor het filteren van het beeld volgens een van te voren bepaald patroon, het losneembaar bevestigen (S5) van de kleurfilterlaag aan de beeldweergavelaag.2. A method of manufacturing a display comprising the steps of providing (S1) an image display layer for displaying an image with at least one brightness component, providing (S2) a color filter layer comprising a color filter for filtering the image. image according to a predetermined pattern, releasably attaching (S5) the color filter layer to the image display layer. 3. Werkwijze volgens conclusie 2, waarin de kleurfilterlaag losneembaar is bevestigd aan de beeldweergavelaag door het losneembaar aanbrengen van een tussensubstraat op de beeldweergavelaag en het aanbrengen van de kleurfilterlaag op een van de beeldweergavelaag afgekeerd oppervlak van genoemd substraat. 20The method of claim 2, wherein the color filter layer is releasably attached to the image display layer by releasably applying an intermediate substrate to the image display layer and applying the color filter layer to a surface of said substrate remote from the image display layer. 20 4. Werkwijze volgens conclusie 2, waarin de kleurfilterlaag losneembaar is bevestigd aan de beeldweergavelaag door het aanbrengen van de kleurfilterlaag op een apart substraat en door het vervolgens losneembaar lamineren van het aparte substraat op de beeldweergavelaag. 25The method of claim 2, wherein the color filter layer is releasably attached to the image display layer by applying the color filter layer to a separate substrate and then releasably laminating the separate substrate to the image display layer. 25 5. Werkwijze volgens conclusie 2, voorts omvattende de stap van het testen (S3) van de verschafte beeldweergavelaag, waarbij de stap van het losneembaar bevestigen (S5) van de kleurfilterlaag slechts dan wordt uitgevoerd als de verschafte kleurfilterlaag de stap van het testen met een positief resultaat (OK) is gepasseerd. 30The method of claim 2, further comprising the step of testing (S3) the provided image display layer, wherein the step of releasably attaching (S5) the color filter layer is performed only if the provided color filter layer performs the step of testing with a positive result (OK) has passed. 30 6. Werkwijze volgens conclusie 2, voorts omvattende een stap van het testen (S6) van het beeldscherm na de stap van het losneembaar bevestigen (S5) van de kleurfilterlaag en een stap van verwijderen (S8) van de kleurfilterlaag van de beeldweergavelaag als het beeldscherm deze test niet met een positief resultaat (NOK) passeert.The method of claim 2, further comprising a step of testing (S6) the display after the step of releasably attaching (S5) the color filter layer and a step of removing (S8) the color filter layer from the image display layer as the display this test does not pass with a positive result (NOK). 7. Werkwijze volgens conclusie 6, gekenmerkt doordat de kleurfilterlaag 5 losneembaar aan de beeldweergavelaag wordt bevestigd door een tussenliggende zwakke lijmlaag en dat de stap van het verwijderen (S8) van de kleurfilterlaag van de beeldweergavelaag indien het beeldscherm de test niet met positief resultaat passeert wordt uitgevoerd door de kleurfilterlaag van de beeldweergavelaag te pellen. 10Method according to claim 6, characterized in that the color filter layer 5 is releasably attached to the image display layer by an intermediate weak adhesive layer and that the step of removing (S8) the color filter layer from the image display layer if the display does not pass the test with a positive result performed by peeling the color filter layer from the image display layer. 10 8. Werkwijze volgens conclusie 6, gekenmerkt doordat de kleurfilterlaag een losneemlaag omvat aan een oppervlak bevestigd aan de beeldweergavelaag en dat de stap van het verwijderen (S8) van de kleurfilterlaag indien het beeldscherm de test niet met positief resultaat passeert wordt uitgevoerd door de losneemlaag met de 15 kleurfilterlaag van de beeldweergavelaag te pellen.A method according to claim 6, characterized in that the color filter layer comprises a release layer on a surface attached to the image display layer and that the step of removing (S8) the color filter layer if the display does not pass the test with a positive result is performed by the release layer with peel the color filter layer from the image display layer. 9. Werkwijze volgens conclusie 6, gekenmerkt doordat de kleurfilterlaag is bevestigd aan de beeldweergavelaag door middel van een tussenlaag die oplosbaar is in een oplosmiddel dat de beeldweergavelaag niet oplost en dat de stap van het 20 verwijderen (S8) van de kleurfilterlaag van de beeldweergavelaag indien het beeldscherm de test niet met positief resultaat passeert wordt uitgevoerd door het selectief oplossen van de tussenlaag in een oplosmiddel.9. Method according to claim 6, characterized in that the color filter layer is attached to the image display layer by means of an intermediate layer that is soluble in a solvent that does not dissolve the image display layer and that the step of removing (S8) the color filter layer from the image display layer if the display does not pass the test with positive result is performed by selectively dissolving the interlayer in a solvent. 10. Apparaat voor het vervaardigen van een beeldscherm omvattende 25. een eerste eenheid (110) voor het verschaffen van een beeldweergavelaag, welke beeldweergavelaag is ingericht voor het met tenminste een helderheidscomponent weergeven van een beeld, een tweede eenheid (120) voor het verschaffen van een kleurfilterlaag voor het filteren van het beeld volgens een van te voren bepaald patroon, welke 30 kleurfilterlaag losneembaar wordt bevestigd aan de beeldweergavelaag.An apparatus for manufacturing a display comprising 25. a first unit (110) for providing an image display layer, which image display layer is adapted to display an image with at least one brightness component, a second unit (120) for providing a color filter layer for filtering the image according to a predetermined pattern, which color filter layer is releasably attached to the image display layer. 11. Apparaat volgens conclusie 10, waarbij de tweede eenheid (120) is ingericht voor het losneembaar bevestigen van een tussensubstraat aan de beeldweergavelaag en voor het bevestigen van de kleurfilterlaag aan een van de beeldweergavelaag afgekeerd oppervlak van het tussensubstraat.The apparatus of claim 10, wherein the second unit (120) is adapted for releasably attaching an intermediate substrate to the image display layer and for attaching the color filter layer to a surface of the intermediate substrate remote from the image display layer. 12. Apparaat volgens conclusie 11, waarbij de tweede eenheid (120) is ingericht 5 voor het bevestigen van de kleurfilterlaag aan een met de beeldweergavelaag te lamineren apart substraat.Apparatus as claimed in claim 11, wherein the second unit (120) is arranged for attaching the color filter layer to a separate substrate to be laminated with the image display layer. 13. Apparaat volgens conclusie 10, verder gekenmerkt door een derde eenheid (124) voor het testen van een kwaliteit van het product 10 verkregen door het losneembaar bevestigen van de kleurfilterlaag aan de beeldweergavelaag, en voor het verschaffen van een foutsignaal indien de kwaliteit van het product niet acceptabel is, een vierde eenheid (150) voor het verwijderen van de kleurfilterlaag van de beeldweergavelaag bij activatie van het foutsignaal. 15The apparatus of claim 10, further characterized by a third unit (124) for testing a quality of the product 10 obtained by releasably attaching the color filter layer to the image display layer, and for providing an error signal if the quality of the product is not acceptable, a fourth unit (150) for removing the color filter layer from the image display layer upon activation of the error signal. 15 14. Apparaat volgens conclusie 13, voorts omvattende een transportfaciliteit (182) voor het transporteren van de beeldweergavelaag waarvan de kleurfilterlaag was verwijderd van de vierde eenheid (150) naar de tweede eenheid (120).The apparatus of claim 13, further comprising a transport facility (182) for transporting the image display layer whose color filter layer was removed from the fourth unit (150) to the second unit (120).
NL2005498A 2010-10-11 2010-10-11 Display as well as method and apparatus for manufacturing a display. NL2005498C2 (en)

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JP2003050376A (en) * 2001-06-01 2003-02-21 Sony Corp Position adjusting mechanism of split wavelength plate filter, 3-d image display unit, filter position adjusting method of 3-d image display unit, and display unit
KR20070024752A (en) * 2005-08-23 2007-03-07 엘지전자 주식회사 Color e-paper display
WO2008132853A1 (en) * 2007-04-23 2008-11-06 Sharp Kabushiki Kaisha Functional glass substrate, laminate of functional glass substrate, method of using functional glass substrate, and method of laminating functional glass substrate

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH03190360A (en) * 1989-12-20 1991-08-20 Canon Inc Picture reader
JP2000010098A (en) * 1998-06-19 2000-01-14 Okaya Electric Ind Co Ltd Liquid crystal display device
JP2003050376A (en) * 2001-06-01 2003-02-21 Sony Corp Position adjusting mechanism of split wavelength plate filter, 3-d image display unit, filter position adjusting method of 3-d image display unit, and display unit
WO2003012542A1 (en) * 2001-07-27 2003-02-13 Sipix Imaging, Inc. Electrophoretic display with color filters
KR20070024752A (en) * 2005-08-23 2007-03-07 엘지전자 주식회사 Color e-paper display
WO2008132853A1 (en) * 2007-04-23 2008-11-06 Sharp Kabushiki Kaisha Functional glass substrate, laminate of functional glass substrate, method of using functional glass substrate, and method of laminating functional glass substrate

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