NO314965B1 - Micro pocket display - Google Patents

Description

FIELD OF THE INVENTION

The present invention relates to a display and a method for producing it. The display comprises an electrode layer, a substrate which, on the surface facing the electrode layer, is covered with a set of electrode elements placed in cavities, and a layer of electro-optical material which is arranged between the electrode layer and the substrate.

BACKGROUND TECHNOLOGYJC

The present invention relates to the technical area of flat displays. An example of a display or screen in accordance with the above (also called LCD, liquid crystal display) is described in SE-511,511, entitled "Display", comprises an electrode layer, a substrate which on the surface facing the electrode layer is covered with a set of electrode elements, and a layer of electro-optic material which is arranged between the electrode layer and the substrate, where the substrate is arranged behind the layer of electro-optic material in relation to the direction of vision, where the substrate is arranged to carry electronic components on one side for controlling the electrode elements, and on the other hand conductive patterns for connecting the electronic components of the electrode element, and where the electrode elements form image elements in the display in cooperation with the electrode layer and the layer of electro-optical material.

A disadvantage of this display is the amount of electro-optical material that is required to be filled between the electrode layer and the substrate. The manufacturing method results in a display with pixel regions filled with a continuous layer of liquid crystals. The electro-optical material is quite expensive, and it is desirable to minimize the amount used.

US-6,266,122 entitled: "Liquid crystal display and method for manufacturing the same" relates to a display which includes a first substrate and a second substrate, and a liquid crystal layer placed between the first substrate and the second substrate. The first substrate includes a polymer wall formed of transparent resin, and the liquid crystal layer includes a plurality of liquid crystal regions that are aligned axially symmetrically with respect to an axis in a direction substantially perpendicular to a surface of the first substrate.

The main focus of this special way of presentation is to achieve a wide viewing angle and improved quality for the displayed information.

The essential advantages of the display according to the present invention described here are reduced production costs compared to other manufacturing methods, thanks to a minimal number of layers, and the use of less expensive electro-optical materials, combined with a thin and compact display.

SUMMARY OF THE INVENTION

The purpose of the present invention is to reduce the number of layers, and a minimal use of electro-optical material, which results in a more cost-effective production method and a robust display.

The above and other advantages are achieved by the manufacturing method according to claim 1. The manufacturing method comprises the steps of providing an insulating substrate and of making cavities in the upper surface for the substrate. For further reference, the cavities are referred to as micropockets. Each micropocket is provided with a hole, preferably in the center, extending from the upper surface of the micropocket, all the way through to the underside of the insulating substrate. A conductive material is applied to the inner surfaces of the micro pocket and into the holes. Thereby, an electrical connection is provided from the underside of the insulating substrate to the inside of the micro-pockets. The micro-pockets are filled with an electro-optical material and supplied with a uniform layer of a transparent common conductor to cover all the micro-pockets with the electro-optical material. A transparent substrate is applied on top of the transparent conductor to form the upper layer.

In a preferred embodiment, the insulating substrate is made of glass fiber composite, plastic or ceramic. _

In another preferred embodiment, the formation of the cavities in the upper layer of the insulating substrate can be formed by embossing, printing, engraving or etching in the insulating substrate.

In yet another preferred embodiment, the formation of the cavities in the upper layer of the insulating substrate can be formed by applying a separate thin plate with holes, where each hole corresponds to one image element or pixel. The board is placed on the insulating substrate with the deposition of conductive material, gluing or heat sealing.

In a preferred embodiment of the invention, the conductive material is ITO, copper or aluminium.

In a preferred embodiment of the invention, the electro-optical material is liquid crystals, LEDs (inorganic or organic), electrochromatic material, or another material that changes its optical properties when an electric field is applied.

In another preferred embodiment of the invention, the common conductor covering the micropockets comprises ITO or SnO. In yet another preferred embodiment, the transparent substrate is made of glass or plastic.

In addition to the manufacturing method for the thin display, the invention also includes the display itself, with the features specified in the appended claims.

In accordance with one aspect, the invention is based on the recognition that in a display of this type it is advantageous to allow the electrode elements, which are usually called pixels, to be connected to a conductive layer by means of conductive connections that originate in the electrode elements in a direction away from made of electro-optical material, i.e. the underside of the insulating substrate. This will contribute to the form factor of the thin display. Another aspect that also contributes to a thin display in accordance with the invention are the cavities that are prepared directly in the insulating substrate,

or which is formed with a separate thin plate with holes placed on the insulating substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by means of exemplary embodiments with reference to the attached drawings, where: Fig. 1 is a schematic cross-sectional view of the components of

the micro pocket display system of the present invention,

Fig. 2 is a schematic cross-sectional view of a composite display in accordance with the present invention, Fig. 3 is a schematic view in accordance with method 1 with micro-pockets for the electro-optical material formed in insulating substrate, Fig. 4 is a schematic view in accordance with method 2 with micro-pockets for electro-optical material formed in a separate thin plate.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to the drawings, the following detailed description explains how the invention has been achieved:

Fig. 1 shows a cross-section of the various components that make up the display.

The base for the display is made of an insulating substrate 80 with small, impressed cavities 60. These cavities 60 will form the picture elements or pixels for the composite display. For further reference, the cavities are referred to as micropockets. The insulating substrate 80 can be made of a glass fiber composite, plastic, ceramic or another material with insulating properties. The micro pockets 60 can be formed by printing, embossing, engraving or etching in the substrate 80. After the micro pockets 60 have been established, holes 70 are preferably produced in the center of each micro pocket 60. These holes 70 will in turn provide electrical connection between the underside of the substrate and each micro pocket 60. This connection will be established when a conductive material 40, 50 is supplied to the substrate 80. By supplying a molten conductive material 40, 50, i.e. copper or aluminum, into the micro pockets 60, the holes 70 will also be filled with the conductive the material 40, 50, so that physical contact is allowed between the micro pockets 60 and electronic components 90 and wires connected on the underside of the insulating substrate 80. The micro pockets 60 are then filled with an electro-optical material, i.e. liquid crystal, LED or electrochromatic material. The layer of electro-optical material 30 is covered with a layer of transparent common conductor 20, i.e. ITO or SnO. The upper layer consists of a transparent substrate 10 such as glass or plastic. Fig. 2 shows a cross-section of a composite display with all the different layers that form the thin display in accordance with the invention. The electrical connection 40, 50 with installed wires and electronic components 90 will ensure activation of the electro-optic medium 30. The electro-optic material 30 is covered with a layer of a transparent common conductor 20. The top layer consists of a transparent substrate such as glass or plastic. Fig. 3 shows a first method for adding micro-pockets 60 in the insulating substrate 80. The cavities or micro-pockets are formed by printing, embossing, engraving or etching on the substrate 80. Fig. 4 shows a second method for adding the micro-pockets in the insulating substrate 80. This method includes the step of forming holes 65 in a separate thin plate where each hole 65 corresponds to one picture element or pixel. The thin plate 55 is placed on the insulating substrate 80 by deposition of conductive material, gluing or heat sealing.

The present invention is not limited to the manufacturing method and the display described here. The display can be produced with different variations,

for example, the holes in the cavities can be applied off-center.

Claims (17)

1. Method for providing a thin display with an insulating substrate comprising: a) creating cavities in the upper surface of the insulating substrate or forming cavities by providing a separate thin plate with holes, placed on the insulating substrate, b) creating holes in the cavity extending from the top surface of the cavity all the way through to the underside of the insulating substrate, c) applying a conductive material to the inner surfaces of each cavity and into the holes, thereby providing an electrical connection from the underside of the insulating substrate to the inside of the cavities, d) filling the cavities with an electro-optical material, e) adding a uniform layer of a transparent common conductor to cover all the cavities filled with the electro-optical material, f) adding a transparent substrate on top of the transparent conductor, which constitutes the upper layer. 2. Method in accordance with claim 1, where in step a) the insulating substrate is made of glass fiber composite, plastic or ceramics. 3. Method in accordance with claim 1, where in step b) the cavities made in the upper side of the insulating substrate are created by printing, embossing, engraving or etching in the insulating substrate. 4. Method in accordance with claim 1, where in step b) the holes in the cavity are made in the center of the cavity. 5. Method in accordance with claim 1, where in step c) the conductive material is ITO, copper or aluminium. 6. Method in accordance with claim 1, where in step d) the electro-optical material is liquid crystals, LED (inorganic or organic), electrochromatic material or another material which ends its optical properties with an applied electric field. 7. Method in accordance with claim 1, where in step e) the common conductor covering the micropockets comprises ITO or SnO. 8. Method in accordance with claim 1, where in step f) the transparent substrate is made of glass or plastic. 9. Thin display, comprising an insulated substrate, cavities in the substrate or formed with a separate thin plate placed on the substrate, perforated holes in the cavities, a conductive material covering the surfaces inside the cavities and the perforated holes, an electro-optical material filling the micro-pockets , a uniform layer of transparent conductive material covering all the filled micro-pockets, and an upper layer of a transparent substrate covering the conductive layer. 10. Display in accordance with claim 9, where said insulating substrate is made of glass fiber composite, plastic or ceramics. 11. Display in accordance with claim 9, where the cavities are printed, embossed, engraved or etched in the circuit board material. 12. • Display in accordance with claim 9, where the perforated holes in the cavities are produced in the center of the cavities. 13. Display in accordance with claim 9, wherein the conductive material comprises ITO, copper or aluminium. 14. Display according to claim 9, where the conductive material which forms an electrical connection from the inside of the cavities to the underside of the insulating substrate is supplied so that electronic components and wires can be placed on the underside of the insulating substrate for activation of the electro-optical medium in each cavity. 15. Crystal display in accordance with claim 9, where the electro-optical material comprises liquid crystals, LEDs, electrochromatic material or other material that changes its optical properties with an applied electric field. 16. Crystal display in accordance with claim 9, where the transparent conductive material covering the cavities is made of ITO or SnO. 17. Crystal display in accordance with claim 9, where the transparent substrate comprises glass or plastic or another transparent material.