RU2690042C1 - Method and device for making a flexible electroluminescent light source - Google Patents

Abstract

FIELD: lighting engineering.SUBSTANCE: invention relates to production of flexible elongated electroluminescent light source. Method of making a flexible electroluminescent light source involves successive deposition of a dielectric powder on a copper wire in a polymer binder, an electroluminescent powder in a polymer binder and a transparent electroconductive polymer, characterized in that the deposition is carried out as follows: from wire supply unit (WSU) with at least one main coil copper wire is supplied to the washing device, as well as at least one additional coil with copper wire is installed in the WSU, at that, the WSU is equipped with a cold welding apparatus intended for welding the wire into the joint, during transition from the main to the additional coil forming at least one line with copper wire; copper wire is passed through node quenching jerk; at that, one line with copper wire corresponds to its node quenching jerk; successively passing continuously moving at least one copper wire through baths with solutions of polymers with fillers in direction from bottom to top and coated with an appropriate layer of polymer, at outlet of baths, wire is passed through calibration die, which cuts off part of solution and forms on copper wire layer of polymer of specified thickness; coming out of the bath and passing through the calibrating die copper wire with a layer of polymer of specified thickness is supplied into vertical column of drying kilns; at outlet of each vertical column of furnaces, wire with dried polymer is cooled; after coating of copper wire with corresponding polymers and drying, the obtained flexible electroluminescent light source (FELLS) is supplied to the FELLS diameter check assembly and further into the FELLS puller assembly, which allows to draw FELLS at a constant rate, and through the FELLS accumulation assembly is supplied to the ready FELLS collection assembly for winding thereof on bobbins.EFFECT: invention provides higher brightness, flexibility and strength of extended light source, uniform illumination both along and around central axis by 360 degrees, increased percentage output of finished products during production, reduced prime cost of finished products.3 cl, 5 dwg

Description

The technical field to which the invention relates.

The invention relates to the production of flexible extended electroluminescent light sources, by coating continuously moving copper wire with layers of dielectric powders in a polymeric binder, electroluminescent powders in a polymeric binder and transparent conductive layer, and flexible light sources can be used in the air, ground, underground and underwater emergency services response; when illuminating escape routes in buildings, air-raid shelters; in the designation of various objects in the evening, in smoke, in fog; in the designation of road users and road workers in the evening, with reduced illumination; “Smart lighting” of cities, “smart” roads, etc.

The level of technology

From the prior art a method of manufacturing an electroluminescent light source, (see [1] RF patent №2096932, IPC H05B33 / 26, publ. 11/20/1997), consisting of operations of forming a system of extended electrodes, an electroluminescent layer of electroluminescent powder in a dielectric binder, and a transparent polymer coating, in which the method is carried out in two stages: in the first, a core is formed, consisting of a system of electrodes arranged in space at a certain distance from each other, which is made using the method of buckle electrodes through the melt, or solution or suspension of the material connecting bodies, and two ribbon structures, the electroluminescent layer based on the binder and the dielectric layer of the EL; in the second stage, the previously formed core and two ribbon structures are combined under pressure so that the electroluminescent film layer fills closely the interelectrode spaces above the surface of the connecting bodies, forming longitudinal film regions. The disadvantages of the analogue are: low luminescence (low brightness); narrow scope because the invention is a panel and can be used mainly for outdoor advertising; the complexity of the technology due to the manufacture of multisection (multielectrode) light source; high cost of production process with the possibility of its implementation.

The prior art is a flexible electroluminescent light source ([2] RF Patent No. 2124281, IPC H05B33 / 26, publ. 12.27.1998), consisting of two filament or wire electrodes on which filled polymer layers of graphite and electrically conductive carbon black are sequentially formed binder, dielectric with high dielectric constant in the binder, electroluminescent powder; in a binder, on top of which is applied a common transparent electrically conductive layer based on an electrically conductive filler in the binder. As a dielectric with a high dielectric constant, dispersed barium titanate or titanium oxide is used, and the conductive filler is indium oxide doped with tin or antimony, or zinc oxide doped with gallium. The content of the doping element is 0.3-1.3 wt. % Butadiene-nitrile rubber is used as a binder. The light source has a shell made of flexible optically transparent dielectric material.

Known electroluminescent cable ([3] US patent No. 6855027, IPC H05B33 / 00, publ. 15.02.2005), containing at least one layer of organic electroluminescent material located on the fibers; There are electrodes on the layer, which create an electric field when the voltage is applied to activate the layer of organic electroluminescent material; A barrier layer is applied over the electrodes to reduce the permeability of oxygen, water vapor and other chemically active substances to the underlying layers. The barrier layer includes either alternating sublayers of polymeric and inorganic material, or alternating sets of sublayers of polymeric materials and adjacent sublayers of inorganic materials. The color of the light can be adjusted by varying the layers containing inorganic and / or organic phosphoric materials.

Known electroluminescent light source ([4] US patent No. 5869930, IPC H05B33 / 00, publ. 09.02.1999), consisting of at least one flexible cable type electroluminescent filament, each filament has a central electrode surrounded by an electrically insulating layer of a dielectric, on top of which is applied a layer consisting of a mixture of electroluminor powder and a binder. The light source also includes a transparent electrode surrounding a layer of a mixture of electroluminescent powder. The pores formed in the layer of the mixture are filled with a transparent filler substance.

The disadvantages of these analogues are low brightness, low mechanical strength, including poor resistance to bending and a short lifetime.

Summary of Invention

The technical problem to be solved by the claimed invention is the creation of a method and device for the production of a luminous yarn of different brightness and glow (flexible electroluminescent light source), using different diameter of the central electrode and coating the continuously moving electrode (copper wire) with the necessary number of layers of dielectric and electroluminescent powders polymer binder, as well as a transparent conductive layer.

The technical result of the claimed invention is to increase the brightness, flexibility and durability of an extended light source, uniform luminescence both along and around the central axis by 360 degrees, an increase in the percentage yield of the finished product during production, and a reduction in the cost of the finished product.

The problem is solved, and the technical result is achieved due to the method of manufacturing a flexible electroluminescent light source, including sequential deposition of a dielectric powder on a copper wire in a polymeric binder, electroluminescent powder in a polymeric binder and transparent electrically conductive polymer, the application being carried out as follows: SCP) with at least one main coil is fed to the washing device a copper wire, and also set into SCP, in m nshey least one additional spool with copper wire, wherein the SCP is equipped cold welding apparatus designed for welding wire joint, at the transition from the main to the additional coil forming at least one line with copper wire; pass the copper wire through the node jerking jerks, while, one line with the copper wire corresponds to its node quenching jerks; alternately pass continuously moving at least one copper wire through baths with polymer solutions with fillers in the direction from the bottom up and cover with an appropriate layer of polymer; at the outlet of the baths the wire is passed through a calibration die, which cuts off part of the solution and forms a polymer layer on the copper wire specified thickness; Copper wire coming out of the bath and past the calibration die, coated with a layer of polymer of a given thickness, is fed to a vertical column of drying ovens; at the outlet of each vertical column of the furnaces, the wire with the dried polymer is cooled; after coating the copper wire with the corresponding polymers and drying, the resulting flexible electroluminescent light source (GELIS) is fed to the GELIS diameter inspection unit and then to the GELIS drawing unit, which allows GELIS to be drawn at a constant speed, and through the GELIS storage unit to the winding unit its on reels.

The technical result is also achieved due to the fact that alternately passing the copper wire through the baths, they first apply from 1 to 3 layers of dielectric powder in a polymeric binder, then from 1 to 3 layers of electroluminescent powder in a polymeric binder and cover these layers with a transparent electrically conductive polymer .

The task is also solved, and the technical result is achieved by a device for manufacturing a flexible electroluminescent light source, comprising: a wire feed unit (SCP) comprising at least one line of the main and additional coils with copper wire, while on the SCP end panel a cold welding machine is fixed, designed to weld the wire into the joint during the transition from the main to the additional coil; a washing device for washing and cleaning the wire is installed at the exit of the SCP; at least one jerking damping unit (UHF) consisting of lower and upper rollers, the upper roller being arranged to move down and up to damping jerks and accumulating the wire, with each junction line with each copper wire; consistently installed at least three baths with solutions of dielectric powder in a polymer binder, electroluminescent powder in a polymer binder and a transparent electrically conductive polymer, with a calibration filler at the outlet of each bath, which cuts off part of the solution and forms a layer of a given thickness on the wire; at least three vertical columns of furnaces, each of which is installed above the corresponding of the baths, each column consists of 4 furnaces with independent control; above the columns of the furnaces, an exhaust device is installed to remove steam from the furnaces and a cooler for cooling the coated wire, while the exhaust device and the cooler are the same for all columns; the node checking the diameter of the obtained flexible electroluminescent light source (GELIS); knot of the broach GELIS, allowing to pull the wire at a constant linear speed; GELIS accumulation unit allowing accumulation of GELIS before its winding on the receiving coil in the receiving unit of the finished GELIS, which makes it possible to change the receiving coils without stopping the process; main control processor with a control panel that allows you to monitor and control the processes and operation of the device.

Brief Description of the Drawings

FIG. 1 shows a device for applying layers on a wire.

FIG. 2 shows a wire feed assembly.

FIG. 3 shows a wire receiving unit.

FIG. 4 shows the calibration die.

FIG. 5 shows a drop-like thickening of the layers due to the action of gravity.

Positions indicated on the figure:

1 - wire feed unit (UPP); 2 - the main coil; 3 - additional coil; 4 - washing device; 5 - jerking damping unit (UGR); 6 - lower roller UGR; 7 - upper roller UGR; 8 - baths with polymer solutions; 9 - oven column; 10 - furnaces; 11 - exhaust device; 12 - cooler; 13 is a unit for checking the diameter of a flexible electroluminescent light source (GELIS); 14 - knot broach GELIS; 15 — GELIS accumulation unit; 16 - take-up reel; 17 — GELIS receiving unit; 18 - the main control processor; 19 - control panel.

The implementation of the invention

The invention is implemented using a method and device for applying conductive layers and an electroluminophore on a copper wire.

A general view of the installation is shown in FIG. 1. FIG. 2 and FIG. 3 shows its kinematic scheme.

The device contains a wire feed unit (pos. 1) (UPP), which includes at least one line from the main (pos. 2) and additional (pos. 3) coils with copper wire. On the end panel of the SCP there is a cold welding apparatus (not shown in the drawing), intended for welding the wire into the joint at the transition from the main coil to the additional coil. The UPP feeds the installation of the copper wire to be coated. UPP allows you to install from 1 to 4 lines of coils with copper wire (i.e., from 1 to 4 main coils and from 1 to 4 additional coils with copper wire), which makes it possible to apply to the installation simultaneously from 1 to 4 lines of wire (in Fig. 1 shows an installation with two lines of copper wire).

At the exit of the SCP (pos. 1), a washing device (pos. 4) is installed, intended for washing and cleaning the copper wire from impurities that may adversely affect the deposition process.

Following the SCP (pos. 1), at least one jerk damping assembly (pos. 5) (UGR) is installed, which consists of the lower (pos. 6) and upper (poses 7) rollers. The upper roller is designed to move up and down to extinguish the jerks that occur during the withdrawal of the wire from the coil, and to accumulate the wire. The margin of the wire on the UGR allows you to stop the UPP for 2-3 minutes to replace the coil and for some other reason. This makes it possible to promptly replace the waste coil with new ones. At the same time, each line of the wire corresponds to its UGR (i.e., when 4 lines of copper wire are supplied to the installation, 4 UGR is installed).

Next, at least three baths (pos. 8) with polymer solutions with fillers are installed in series. The first with a solution of dielectric powder in a polymer binder, the second with a solution of an electroluminescent powder in a polymer binder, the third with a solution of a transparent electrically conductive polymer. In this case, there may be several baths with a dielectric powder in the polymer binder, for example, up to 3 pcs., The same number of baths can be with an electroluminescent powder in the polymer binder. Thus, the minimum number of baths can be equal to three, the maximum - seven.

At the outlet of each bath, a calibration filler is installed (FIG. 4), which cuts off part of the solution and forms a layer of a given thickness on the wire.

A column of furnaces (pos. 9) is installed above each bathroom, with each column consisting of 4 furnaces (pos. 10) with independent control of the temperature in each. The number of columns of furnaces (pos. 9) is proportional to the number of baths with polymers. The column of furnaces is intended for drying the wire leaving the bath.

Above the furnace columns (pos. 9), an exhaust device (pos. 11) is installed to remove steam from the furnaces and a cooler (pos. 12) for cooling the coated wire, while the exhaust device and the cooler are the same for all columns.

The following steps are subsequently installed: a diameter inspection unit (pos. 13) of a flexible electroluminescent light source (GELIS) already obtained; the pulling unit (pos. 14) of GELIS, which allows to draw the wire with a constant linear speed; accumulation unit (pos. 15) GELIS allowing accumulating GELIS before its winding on the receiving reel (pos. 16) in the receiving unit (pos. 17) of the finished GELIS, which makes it possible to change the receiving reels without stopping the process. The wire storage unit, as well as the UGR, consists of the lower and upper rollers. The upper roller is adapted to move down and up to accumulate the wire. At the same time, the number of wire storage nodes corresponds to the number of lines with wire (in this case, the GELIS already received).

All device operation parameters are monitored using a control processor (pos. 18) with a control panel (pos. 19).

The device is implemented by a method of manufacturing a flexible electroluminescent light source, including the sequential deposition on the copper wire of a dielectric powder in a polymeric binder, an electroluminescent powder in a polymeric binder, and a transparent electrically conductive polymer.

Layers of polymer solutions with fillers are applied on a continuously moving copper wire by dipping, that is, through the passage of the wire through the composition corresponding to the stage. From the wire feed unit (UCP) with at least one main coil, copper wire is fed into the washing device. At least one additional coil with copper wire is installed in the SCP. In this case, the SCP is equipped with a cold-welding machine designed for butt-welding of the wire, when moving from the main to the additional coil, forming at least one line with copper wire.

Next, pass the copper wire through the node quenching jerk, at the same time, one line with the copper wire corresponds to its node quenching jerks.

After the jerking unit, alternately continuously pass at least one copper wire through baths with solutions of polymers with fillers in the direction from the bottom up and cover with a suitable layer of polymer. At the outlet of the baths, the wire is passed through a calibration die, which cuts off part of the solution and forms a layer of polymer of a given thickness on the copper wire. wire carries on a certain (specified) amount of the solution.

Next, the wire passes through the battery of furnaces, where each layer is dried, namely: the copper wire leaving the bath and passed the calibration die, with a coated layer of polymer of a given thickness, is fed to a vertical column of drying ovens. At the exit of each vertical column of the furnaces, the wire with the dried polymer is cooled.

After coating the copper wire with suitable polymers and drying, the resulting flexible electroluminescent light source (GELIS) is fed to the GELIS diameter inspection unit and then to the GELIS broach assembly, which allows GELIS to be drawn at a constant speed, and through the GELIS accumulation assembly, is fed to the finished GELIS winding receiving unit its on reels.

Alternately passing the copper wire through the baths, they first apply from 1 to 3 layers of dielectric powder in a polymeric binder, then from 1 to 3 layers of electroluminescent powder in a polymeric binder and cover these layers with a transparent electrically conductive polymer.

The main process in creating an electroluminescent long flexible light source is the process of creating a luminous filament by coating continuously moving copper wire (wire diameter from 0.4 mm to 0.7 mm) with layers of dielectric and electroluminescent powders in polymer binders and a layer of electrically conductive polymer. In the proposed installation, the vertical arrangement of the columns of furnaces for drying copper wire with layers deposited on it is essential; each furnace in the column has independent temperature control. The design of the calibration die is also original - it is “floating” (that is, it has several degrees of freedom of movement), which allows the moving copper wire to self-center in the center of the spinneret.

In this case, the applied layers are arranged around the copper wire evenly in a circle. In this case, the vertical movement of the wire through the furnace eliminates the drop-like thickening of the layers due to the action of gravity, as shown in FIG. 5, which allows to increase the brightness, flexibility, durability of GELIS, as well as to achieve a uniform luminescence both along and around the central axis (ie, the central electrode) by 360 degrees.

The speed of the wire varies from 6 to 15 mm / s, the drying temperature in furnaces is from 80 to 200 ° C. The concentration of "solutions" - from 10 to 40 weight percent.

The technical result is achieved due to the managed:

- temperature conditions individually for each furnace in the column;

- pulling speed of the central electrode (copper wire);

- the diameter of the die (and its design features);

- viscosities of bath solutions.

The variability of the modular device allows, depending on the need, to use from 1 to 7 independent production columns of equipment (baths with vertical columns of furnaces), which ensures a high profitability of the installation.

Claims (19)

1. A method of manufacturing a flexible electroluminescent light source, including the sequential deposition on the copper wire of a dielectric powder in a polymeric binder, an electroluminescent powder in a polymeric binder and a transparent electrically conductive polymer, characterized in that the deposition is as follows: From the wire feed unit (SCP) with at least one main coil, copper wire is fed into the washing device, and at least one additional coil with copper wire is installed in the SCP, and the SCP is equipped with a cold-welding device designed for welding the wire into the joint, when moving from the main to the additional coil, forming at least one line with the copper wire; pass the copper wire through the node jerking jerks, with one line with the copper wire corresponds to its node quenching jerks; alternately pass continuously moving at least one copper wire through baths with polymer solutions with fillers in the bottom-up direction and cover it with an appropriate layer of polymer; at the outlet of the baths the wire is passed through a calibration die, which cuts off part of the solution and forms a layer on the copper wire polymer of a given thickness; Copper wire coming out of the bath and past the calibration die, coated with a layer of polymer of a given thickness, is fed to a vertical column of drying ovens; at the outlet of each vertical column of the furnaces, the wire with the dried polymer is cooled; after coating the copper wire with appropriate polymers and drying, the resulting flexible electroluminescent light source (GELIS) is fed to the GELIS diameter inspection unit and then to the GELIS drawing unit, which allows GELIS to be drawn at a constant speed, and through the GELIS storage unit, is fed to the finished GELIS receiving unit for winding its on reels. 2. The method according to p. 1, characterized in that alternately passing the copper wire through the baths are applied first from 1 to 3 layers of dielectric powder in the polymer binder, then from 1 to 3 layers of electroluminescent powder in the polymer binder and cover these layers transparent electrically conductive polymer. 3. A device for manufacturing a flexible electroluminescent light source, comprising: the wire feed unit (SCP), including at least one line of the main and additional coils with copper wire, while on the end panel of the SCP a cold-welding device is fixed, designed for welding the wire into the joint at the transition from the main to the additional coil; a washing device for washing and cleaning the wire is installed at the exit of the SCP; at least one jerking damping unit (UHF) consisting of lower and upper rollers, the upper roller being arranged to move down and up to damping jerks and accumulating the wire, with each junction line with each copper wire; consistently installed at least three baths with solutions of dielectric powder in a polymer binder, electroluminescent powder in a polymer binder and a transparent electrically conductive polymer, with a calibration filler at the outlet of each bath, which cuts off part of the solution and forms a layer of a given thickness on the wire; at least three vertical columns of furnaces, each of which is installed above the corresponding of the baths, each column consists of 4 furnaces with independent control; above the columns of the furnaces, an exhaust device is installed to remove steam from the furnaces and a cooler for cooling the coated wire, while the exhaust device and the cooler are the same for all columns; the node checking the diameter of the obtained flexible electroluminescent light source (GELIS); knot of the broach GELIS, allowing to pull the wire at a constant linear speed; the GELIS accumulation unit, which allows accumulating the GELIS before winding it on the receiving coil in the receiving unit of the finished GELIS, which makes it possible to change the receiving coils without stopping the process; main control processor with a control panel that allows you to monitor and control the processes and operation of the device.

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