TWI425288B - 具彩色濾光片之光電顯示器 - Google Patents

具彩色濾光片之光電顯示器 Download PDF

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TWI425288B
TWI425288B TW099105762A TW99105762A TWI425288B TW I425288 B TWI425288 B TW I425288B TW 099105762 A TW099105762 A TW 099105762A TW 99105762 A TW99105762 A TW 99105762A TW I425288 B TWI425288 B TW I425288B
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color filter
conductive layer
filter array
polymer
hardenable
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Richard J Paolini
Steven Joseph Battista
Jonathan D Albert
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E Ink Corp
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Description

具彩色濾光片之光電顯示器 【相關申請案之對照參考資料】
本申請案係有關於：
(a)美國專利公開第2004/0190114號；
(b)美國專利第6,864,875號；以及
(c)美國專利第7,075,502號。
本發明係有關於光電顯示器及用於這樣的顯示器中之彩色濾光片。
在美國專利第7,012,600號中詳述關於光電顯示器之背景學術用語及當時的技術水準，讀者可參考該美國專利以得到進一步資訊。於是，下面將簡要概述此背景學術用語及當時的技術水準。
被應用至材料或顯示器之術語「光電」在此係使用其在成像技術中之傳統意思，所指的是一具有在至少一光學特性方面有差異之第一及第二顯示狀態的材料，該材料藉由一電場之施加可從其第一顯示狀態轉變至其第二顯示狀態。雖然該光學特性通常對人眼來說是色彩可感知的，但是它可以是另一光學特性，例如：光透射、反射比、照明、發光性，或者在意欲用於機器讀取之顯示器的情況中，在可見範圍之外的電磁波長的反射變化之觀念中的偽色彩(pseudo-color)。
術語「雙穩態的」及「雙穩定性」以在該技藝中之傳統意思在此用以提及包括顯示元件之顯示器，其中該等顯示元件具有在至少一光學特性方面有差異之第一及第二顯示狀態，以及在以一有限期間之定址脈衝驅動任何既定元件後，以在傳送該定址脈衝後呈現它的第一或第二顯示狀態，該狀態將持續有該顯示元件之狀態改變所需之該定址脈衝的最小期間的數倍(例如：至少4倍)時間。
已知數種型態之光電顯示器，例如：
(a)旋轉雙色構件式顯示器(rotating bichromal member displays)(見例如：美國專利第5,808,783；5,777,782；5,760,761；6,054,071；6,055,091；6,097,531；6,128,124；6,137,467；以及6,147,791號)；
(b)電致變色顯示器(electrochromic displays)(見，例如：O'Regan,B.,et al.,Nature 1991,353,737；Wood,D.,Information Display,18(3),24(March 2002)；Bach,U.,et al.,Adv. Mater.,2002,14(11),845；以及美國專利第6,301,038；6,870,657；及6,950,220)；
(c)電潤濕顯示器(electro-wetting displays)(見Hayes,R.A.,et al.,"Video-Speed Electronic Paper Based on Electrowetting",Nature,425,383-385(25 September 2003)以及美國專利公開第2005/0151709號)；
(d)粒子電泳式顯示器(particle-based electrophoretic displays)，其中複數個帶電粒子在電場影響下移動經過一流體(見美國專利第5,930,026；5,961,804；6,017,584；6,067,185；6,118,426；6,120,588；6,120,839；6,124,851；6,130,773；以及6,130,774號；美國專利申請案公開第2002/0060321；2002/0090980；2003/0011560；2003/0102858；2003/0151702；2003/0222315；2004/0014265；2004/0075634；2004/0094422；2004/0105036；2005/0062714；以及2005/0270261號；以及國際申請案公開第WO 00/38000；WO 00/36560；WO 00/67110；以及WO 01/07961號；以及歐洲專利第1,099,207 B1；以及1,145,072 B1號；以及在前述美國專利第7,012,600號中所論述之MIT及E Ink專利及申請案。
具有數種不同變型之電泳介質(electrophoretic media)。電泳介質可使用液態或氣態流體；對於氣態流體，見例如：Kitamura,T.,et al.,"Electrical toner movement for electronic paper-like display",IDW Japan,2001,Paper HCS1-1,and Yamaguchi,Y.,et al.,"Toner display using insulative particles charged triboelectrically",IDW Japan,2001,Paper AMD4-4)；美國專利公開第2005/0001810號；歐洲專利申請案第1,462,847；1,482,354；1,484,635；1,500,971；1,501,194；1,536,271；1,542,067；1,577,702；1,577,703；及1,598,694號；以及國際申請案第WO 2004/090626；WO 2004/079442；以及WO 2004/001498號。該等介質可以被裝入膠囊，其包括許多小膠囊，每一小膠囊本身包括一在一液態懸浮介質中所懸浮之含電泳流動粒子之一內相(internal phase)及一包圍該內相之膠囊壁。通常，該等膠囊本身係被容納在一聚合物黏合劑中，以形成一被定位在兩個電極間之黏著層(coherent layer)；見前述MIT及E Ink專利及申情案。在另一情況中，包圍在一囊封電泳介質中之分離微膠囊的壁可以以一連續相來取代，因而提供一所謂聚合物分散電泳式顯示器，其中該電泳介質包括一電泳流體之複數個分離小滴及一聚合物材料之連續相；見例如：美國專利第6,866,760號。為了本申請案之目的，將這樣的聚合物分散電泳介質視為囊封電泳介質之亞種。另一變型係一所謂「微細胞電泳式顯示器」，其中將帶電粒子及流體容納在一載體介質(carrier medium)(通常是一聚合物膜)中所形成之複數個空腔內；見例如：美國專利第6,672,921及6,788,449號。
一囊封電泳式顯示器通常免於遭受傳統電泳裝置之群聚及設定故障的損害，並提供另外的優點，例如：將顯示印刷或塗佈在各種撓性及剛性基板上(文字「印刷」之使用意欲包括所有形式之印刷及塗佈，其包括但不侷限於：預先計量式塗佈(pre-metered coating)(例如：方塊模具式塗佈(patch die coating)、狹縫或擠壓式塗佈(slot or extrusion coating)、斜板或瀑布式塗佈(slide or cascade coating)、淋幕式塗佈(curtain coating))；滾筒式塗佈(roll coating)(例如：刮刀滾筒式塗佈(knife over roll coating)、前後滾筒式塗佈(forward and reverse roll coating))；凹版印刷式塗佈(gravure coating)；浸沾式塗佈(dip coating)；噴灑式塗佈(spray coating)；液面彎曲式塗佈(meniscus coating)；旋轉式塗佈(spin coating)；刷塗式塗佈(brush coating)；氣刀式塗佈(air knife coating)；絲網印刷製程(silk screen printing processes)；靜電印刷製程(electrostatic printing processes)；熱印刷製程(thermal printing processes)；噴墨印刷製程(ink jet printing processes)；以及其它相似技術)。因此，產生之顯示可以是變通的。再者，因為該顯示介質為可印刷(使用各種方法)，所以可使該顯示本身成為廉價的。
雖然電泳介質常常是不透光的(因為，例如：在很多電泳介質中，粒子實質上阻擋了可見光經由該顯示器之傳輸)及在一反射模式(reflective mode)中操作，但是許多電泳式顯示器可在一所謂「快門模式(shutter mode)」中操作，其中一顯示狀態大致是不透光的而另一顯示狀態是可透光的。見例如：前述美國專利第6,130,774及6,172,798號及美國專利第5,872,552；6,144,361；6,271,823；6,225,971；以及6,184,856號。相似於電泳式顯示器但依賴電場強度之變化的介電泳式顯示器可在一相似模式中操作；見美國專利第4,418,346號。
其它型態之光電介質在本發明中亦可以是有用的。
在任何既定介質具有兩個極端光學狀態及灰階之範圍係在該兩個極端光學狀態間之觀念上，許多型態之光電介質實質上是單色的。如已所示，該兩個極端光學狀態沒有必要是黑色及白色。例如，一極端光學狀態可以是白色的而另一極端光學狀態是暗藍色的，以致於該等中間灰階將是藍色的變化色度，或者，一極端光學狀態可以是紅色的而另一極端光學狀態是藍色的，以使該等中間灰階將是紫色的變化色度。
甚至對於小的可攜式顯示器而言，現今逐漸需要全彩顯示器；例如：現今在行動電話上之大部分的顯示器係全彩的。要提供一使用單色介質之全彩顯示器，需要設置一彩色濾光片陣列，其中經由該彩色濾光片陣列可觀看該顯示器，或設置能顯示彼此相鄰之不同色彩的不同光電介質的區域。
然而，在正確的位置將一彩色濾光片安裝至一光電顯示器係很難之操作。很多彩色濾光片陣列係形成於玻璃板或相似剛性材料上，以便該彩色濾光片維持穩定尺寸(甚至一彩色濾光片之尺寸的稍微變形會導致該彩色濾光片陣列之至少一部分與該顯示器之像素的失準，因而對觀看者顯示色彩上的誤差)。由於相似的理由，在色彩光電顯示器中所使用之大部分的底板係由剛性材料所形成。該光電介質係固定至該等剛性薄板中之一，及然後，將該兩個剛性薄板疊合在一起，通常，在它們之間具有一聚胺酯層或其它貼合用黏著層，以形成最後之顯示器。該貼合用黏著層可以具有約25μm厚。該貼合用黏著層在室溫中係尚未乾透的(發黏的)，其很難將該兩個剛性薄板疊合一起而使它們之間沒有氣阱，特別是在該等薄板係大尺寸的情況下。儘管特殊對準工具之使用保持該剛性薄板平坦，及在室溫下施加100psig(約0.8MPa)大量壓力，還是發現到，實際很難避免顯著數量之氣泡被捕阱。藉由在高溫度及壓力之條件下使該疊合顯示器通過兩個滾輪間或藉由在高溫度及壓力之條件下再次熱壓顯示器，可減少該等氣泡之數量或去除該等氣泡。這樣的用於氣泡移除的手段實質上增加顯示器組裝製程之成本及時間，使得它在時間及勞力上變得非常密集，以及沒有一貫地產生高品質彩色顯示器。再者，此剛性薄板(通常是玻璃板)之疊合的製程似乎沒有允許一良好製造製程，因為它額外增加了會使該疊合變得非常困難之大的額外電氣及變流限制。
於是，需要一種用於將彩色濾光片陣列疊合至底板的製程，以形成可去除或至少減少上述問題之光電顯示器，以及本發明試圖提供這樣的製程。
本發明提供一種用以組裝一光電顯示器之製程，其中該製程使光電層至底板之疊合與彩色濾光片陣列至底板之疊合及對準去關連(decouple)。
於是，在一態樣中，本發明提供一種用以產生一彩色光電顯示器之製程，該製程包括：提供一光電次組合，包括一光電層及一可透光導電層；疊合該光電次組合至一包括複數個電極之底板，以便在該底板與該導電層間配置該光電層；配置一可流動材料於該導電層上方；以及配置一彩色濾光片陣列於該導電層上方及使該彩色濾光片陣列與該底板之電極對準，以形成該彩色光電顯示器。
在此製程中，通常在該光電層與該底板間提供一黏著層。然而，假設可達成該光電層至該底板之充分黏著，則不需經常提供這樣的分離光電層；例如，根據美國專利第7,110,164號知道，在某些情況中，在一光電層中之一聚合物黏合劑成分可充當一黏著劑，因此，省去一分離黏著劑之需求。
在此製程之一形式中，該光電次組合具有一前板疊層之形式，其中該前板疊層包括該導電層、該光電層及一在該光電層之遠離該導電層的相對側上所配置之黏著層，以及藉由使該黏著層與該底板接觸來實施該疊合。該前板疊層可以進一步包括一覆蓋遠離該光電層之該黏著層的表面之脫模片(release sheet)，以及在將該前板疊層疊合至該底板之前，移除此脫模片。如美國專利第6,982,178號所述，該脫模片可以包括一導電層，以允許該前板疊層之光電特性的測試；藉由使用一金屬化聚合物薄膜做為該脫模片以方便提供這樣的導電層。在本發明之製程的另一形式中，該光電次組合具有一倒置前板疊層之形式，其中該倒置前板疊層依序包括該導電層、一第一黏著層、該光電層及一第二黏著層，以及藉由使該第二黏著層與該底板接觸來實施該疊合。該倒置前板疊層可以進一步包括一覆蓋遠離該光電層之該第二黏著層的表面之脫模片，以及在將該倒置前板疊層疊合至該底板之前，移除此脫模片。
此製程之另一變型使用一如美國專利第7,561,324號所述之所謂「雙脫模片」。此雙脫模片實質上是美國專利第6,982,178號之前板疊層的一簡單變型。該雙脫模片之一形式包括一夾在兩個黏著層間之固態光電介質層，該等黏著層中之一或兩者(通常是兩者)係被一脫模片所覆蓋。要在本製程中使用這樣的雙脫模片，從該雙脫模片移除該等脫模片中之一，及以該暴露黏著層與該底板接觸之方式使該等剩餘層疊合至該底板。接著，移除該第二脫模片，以及在一第二疊合中，使一導電層疊合至在該第一疊合中所產生之底板/光電層次組合。在另一情況中，但是通常很少期望如此，可以相反順序實施該等疊合，其中該第一疊合固定該光電層至該導電層，以形成一倒置前板疊層，以及該第二疊合如以上所述固定此倒置前板疊層(FPL)至該底板。該製程之使用雙脫模片的兩個變型允許該導電層及該光電層彼此獨立地被選擇，以及上述從製造觀點來說係非常有用的；製造者可能具有需要不同型態之導電層但相同光電層的不同顧客；以及要符合顧客需求，可以使用該共同光電層大量地製造雙脫模片，以及然後，當從顧客接收到一特定定單時，疊合該雙脫模片至該被選導電層。
此製程之另一變型使用一如美國專利公開第2007/0109219號所述之所謂「倒置前板疊層」，其實質上是美國專利第6,982,178號所述之前板疊層的變型。一倒置前板疊層依序包括一可透光保護層及一可透光導電層中之至少一者；一黏著層；一固態光電介質層；以及一脫模片。此倒置前板疊層用以形成一在該光電層與該前電極或前基板間具有一疊合黏著層之光電顯示器；一第二黏著薄層(通常是薄層)可以或可以不存在於該光電層與一背板間。這樣的光電顯示器可結合良好解析度與良好低溫性能。
在本發明之製程中，該光電次組合可以進一步包括一在該導電層之遠離該光電層的相對側上所配置之前基板，該前基板提供對該導電層之機械支撐及保護。在某些情況中，這樣的前基板之存在係需要的，因為該導電層不能自我支撐；例如，當該導電層係由濺鍍ITO所形成時，該ITO通常約1μm厚且不能自我支撐。此前基板可以具有不大於50μm之厚度，以及期望地不大於25μm；該前基板留在最後顯示器中，以及如果它太厚，則它可能造成光電層之該彩色濾光片陣列之視差問題(parallax problems)。不論前基板是否存在，該光電次組合可以包括一遮罩被膜(masking film)；這樣的遮罩被膜可用以實質上增加該次組合之厚度，因而有助於該次組合之處理，以及亦可以用以防止對該導電層及/或前基板(如果存在)之機械損害。該遮罩被膜在該彩色濾光片陣列之疊合前被移除。該遮罩被膜可以具有100-200μm之厚度(雖然如果期望的話，可以使用較厚的薄膜)，以例如保護在該底板上所存在之積體電路。
本製程允許各種可流動材料被使用，及將該可流動材料引入該導電層與該彩色濾光片陣列間之各種方法也可被使用。在本製程之一變型中，藉由在被疊合至該底板之該光電次組合的暴露表面上配置複數個間隙子(spacers)、配置該彩色濾光片陣列於該複數個間隙子上、引入一可硬化聚合物於該暴露表面與該彩色濾光片陣列間及硬化該可硬化聚合物，以實施在該導電層上方之該可流動材料及記該彩色濾光片陣列之配置。這樣的製程可以進一步包括配置一可硬化邊緣密封聚合物於該光電層之周圍，但是在該邊緣密封聚合物中留下複數個空隙、硬化該邊緣密封聚合物，以形成一具有延伸穿過之複數個孔的邊緣密封件、施加真空至該等孔中之至少一者，同時連接至少一其它孔至該可硬化聚合物之供應，藉此將該可硬化聚合物汲取至該導電層與該彩色濾光片陣列之間。
在本製程之另一變型中，該可流動材料係一被分配至該導電層之可硬化聚合物，以及在該可硬化聚合物上方配置該彩色濾光片陣列及使其對準後，硬化該可硬化聚合物，以固定該彩色濾光片陣列至該導電層。在此製程變型中，可以以兩個階段有利地實施該聚合物之硬化；在該可硬化聚合物上方配置該彩色濾光片陣列及使其對準後，硬化該可硬化聚合物之複數個分離部分，處理該可硬化聚合物，以從其移除氣泡，以及硬化該未硬化聚合物之剩餘部分，以產生該最後顯示器。
在本發明之又另一變型中，該可流動材料係一在室溫(約21℃)時不是發黏之黏著層。在另一情況中，該可流動材料可以是一在該最後顯示器中維持不變之不可硬化材料，例如：潤滑脂(grease)，較佳是聚矽氧潤滑脂(silicone grease)。當使用這樣的不可硬化材料時，該製程可以進一步包括在該彩色濾光片陣列之對準後，分配一可硬化聚合物於該光電層及該彩色濾光片陣列之周圍，以及硬化此聚合物，以形成一用以彼此固定該光電層及彩色濾光片陣列之邊緣密封件。
在本發明之需要藉由熱壓或任何其它製程從該可流動材料移除氣泡之任何製程中，需要確保該彩色濾光片陣列在該氣泡移除製程期間沒有相對於該底板移動。雖然機械夾緊裝置可用以固定該彩色濾光片陣列，但是實際上更方便的是點硬化(spot cure)該可流動材料本身(如果使用一不可硬化可流動材料)，或者點硬化一可硬化邊緣密封材料，以相對於該底板固定該彩色濾光片陣列於適當位置。
本製程中所使用之該光電層可以是上面所論述之任何型態。因此，例如：該光電層可以包括一旋轉雙色構件或電致變色材料。在另一情況中，該光電材料可以包括一電泳材料，其中該電泳材料包括在一流體中所配置且能在電場之影響下經由該流體移動之複數個帶電粒子。可以將該等帶電粒子及該流體局限在複數個膠囊或微細胞中。在另一情況中，該等帶電粒子及該流體可能是以由一包括聚合物材料之連續相(continuous phase)所包圍之複數個分離小滴的形式存在。該流體可以是液態或氣態。
本發明亦提供一種光電顯示器，依序包括：一底板，包括複數個電極；一光電層；一可透光導電層；一不可硬化及可流動材料層；以及一彩色濾光片陣列。
在這樣的顯示器中，該可流動材料可以是潤滑脂，例如：聚矽氧潤滑脂。
如所述，本發明提供一種用以形成一光電顯示器之製程，其中先將一光電層及一導電層(通常是一前板疊層之形式)疊合至一底板。之後，在該導電層上方沉積一可流動材料，以及在該導電層上方放置一彩色濾光片陣列(CFA，color filter array)，可用任一順序實施這兩個步驟。在本製程之某些形式中，在該彩色濾光片陣列處於適當位置後，硬化該可流動材料；在其它情況，使用一不可硬化材料，以使該材料在該最後顯示器中維持不變。
在本製程中，較佳地以一前板疊層(FPL,front plane laminate)之形式提供該光電層。此前板疊層可以是一如美國專利第6,982,178號之「典型的」前板疊層或一如美國專利申請案公開第2007/0109219號所述之倒置前板疊層。在任一情況中，期望使該前板疊層之基板鄰近該彩色濾光片陣列薄部，以便最小化因該彩色濾光片陣列與該光電層間之間隔所造成的視差及色差。在所附圖式之第1圖中示意性地顯示一適用於本製程中之典型前板疊層(通常以100來表示)。該前板疊層100包括一薄前基板102，該薄前基板102通常是一例如由聚對苯二甲酸二乙酯(polyethylene terephthalate,PET)所形成之透明聚合物薄膜。此前基板102可以具有約6至約50μm之厚度；具有約13μm厚之薄膜在市場上係可獲得的且非常適用於本製程中。一薄前基板之使用係重要的，因為該彩色濾光片陣列(下面所述)藉由該前基板之厚度(以及藉由下面所述之導電層的厚度，但是該導電層通常比該前基板薄很多)與該光電層分隔，以及如果該前基板之厚度太大，則可能遭遇視差問題，因而使該彩色顯示器上之影像的品質下降。該前板疊層100進一步包括一可透光導電層104，該可透光導電層104可以由例如氧化銦錫(indium tin oxide,ITO)、奈米碳管或有機導體所形成。只要該導電層具有充分傳導性，以切換該光電層，該導電層之確切本質不是最重要的；通常小於104 歐姆/平方之電阻率係足夠的。塗有ITO之PET膜在市場上係可獲得的，及可以用以形成該前板疊層100之層102及104。
該前板疊層100之下一層係該光電層106，該光電層106在此情況中是一包括在一聚合物黏合劑中之複數個膠囊的囊封電泳層。如前述美國專利第6,982,178號所述，可以將此光電層直接塗佈至該導電層104上。在該電泳層106之遠離該基板102的相對側上沉積一疊合黏著層108；例如在美國專利第7,012,735及7,477,444中論述之合適黏著劑。最後，該前板疊層100包括一脫模片110。
第2圖描述一可使用於本製程中之倒置前板疊層200。該倒置前板疊層200不同於第1圖所示之典型前板疊層100在於其在該導電層104與該光電層106間插入有一第二黏著層208。在前述美國專利第2007/0109219號中已詳述包含此第二黏著層208的理由。
第3圖描述一第二倒置前板疊層300，其中該第二倒置前板疊層300因加入一覆蓋該基板102之遮罩被膜312而不同於第2圖所示之倒置前板疊層200。如美國專利申請案公開第2008/0174853號所述，在一薄前板疊層或相似多層薄膜中有用地包括一遮罩被膜，以有助於該薄膜之處理，及/或在製造或顯示器組裝操作期間提供對一基板之機械保護。
亦可藉由加入一相似於第3圖所示之遮罩被膜來修改第1圖所示之前板疊層100。
如所述，本發明之製程中的第一步驟係一前板疊層至一底板之疊合；此底板可以是直接驅動形式(其中每一電極具有一個別導體，以獨立地控制在每一電極上之電壓)或主動矩陣形式(其中以列行之2維矩陣來配置像素電極，且具有一非線性裝置(通常是一薄膜電晶體)與每一像素相連，以及在每一列中所有電極連接至一列電極，及在每一行之所有電極連接至一行電極)。光電介質之某些形式亦可以允許一被動矩陣底板之使用。
第4圖係在一前板疊層402(它可以是上述任何形態)至一底板(通常以404來表示)之疊合後，本發明之一較佳製程的上視圖。如第4圖所示，該底板404包括一基板406，該基板406之中間部分係被一主動矩陣底板408所佔據；將該前板疊層402疊合至此主動矩陣底板408上，以使該前板疊層之小周圍部分延伸超過該底板408之邊緣。在該基板406上提供鄰近該前板疊層402所佔據之區域的對準標記410。亦在該基板406上之與該底板408隔開的位置處提供晶片接合區域412。
可以藉由在前述E Ink專利及申請案所述之任何方法實施該前板疊層402至該底板408之疊合。基本上，使該脫模片110(見第1-3圖)從該前板疊層剝離，以及通常在高溫及高壓下使該前板疊層疊合至該底板。一旦這樣疊合該前板疊層，以產生如第4圖所示之中間結構，則可使用本發明之第一製程來安裝一彩色濾光片陣列。
如所述，此製程需要在該前板疊層與一彩色濾光片陣列間引入一可流動液態材料。在本發明之範圍內，可以使用不同方法，引入該可流動液態材料。一方法係相似於用以組裝液晶顯示器之方法。在該前板疊層之周圍分配間隙子(通常是具有嚴密受控直徑的球體)與一可硬化聚合物的混合物，以形成一周邊密封件，但是在此密封件中保留多個空隙。然後，將該彩色濾光片陣列放置在間隙子與聚合物之混合物上。通常，藉由使該彩色濾光片陣列上之對準標記與該底板上之相似標記對準，以實現該彩色濾光片陣列相對於該底板之準確位置；該未硬化聚合物允許該彩色濾光片陣列相對於該底板之移動。接著，硬化該聚合物，以相對於該底板來固定該彩色濾光片陣列。將在該周邊密封件中由該等前述空隙所產生之一個或多個孔連接至真空，同時其它孔連接至一低黏性可硬化聚合物之供應，藉由該真空將該低黏性可硬化聚合物汲取至該前板疊層與該彩色濾光片陣列間。最後，硬化該低黏性可硬化聚合物，以形成該最後顯示器。在某些情況中，可以有利地在已將該前板疊層疊合至該底板後，在該前板疊層之周圍放置一窄周邊的(通常)不同可硬化聚合物，此不同可硬化聚合物可被選擇，以避免在該顯示器之邊緣上的切換性能問題。該窄周邊之聚合物亦密封該前板疊層，因而當該前板疊層在該填充製程期間暴露至真空時，防止水分之損失及/或環境污染物之進入。可下面所述之本製程的其它變型中使用該前板疊層之一相似周邊密封件。
在本製程之一這樣的變型中，在將該前板疊層疊合至該底板後，在該前板疊層之上面分配一可硬化聚合物。選擇該可硬化聚合物之分配圖案，以最小化該前板疊層與在該前板疊層上方所放置之該彩色濾光片陣列間的氣阱；例如，此圖案可以採取在該前板疊層之中間之單水池(single puddle)、從該前板疊層之中心輻射之線條的圖案或「X」狀之形式。然後，將該彩色濾光片陣列向下帶至該可硬化聚合物上，及向下輕壓該彩色濾光片陣列，以使該可硬化聚合物擴散及處於該前板疊層及彩色濾光片陣列相對表面的整個區域。可小心地控制在該前板疊層上所放置之可硬化聚合物的量，以使該前板疊層及彩色濾光片陣列相對表面的整個區域被覆蓋，但是沒有可硬化聚合物之過度洩漏超過該彩色濾光片陣列之邊緣。在此時，可使用像第4圖所示之那些對準標記，使該彩色濾光片陣列對準，以及硬化該可硬化聚合物之鄰近該前板疊層之周圍的數個小區域，以使該彩色濾光片陣列相對於該底板固定於適當位置。然後，可藉由熱壓或任何其它已知技術移除在該聚合物中所剩下之任何氣泡。在該等氣泡之去除後，硬化該未硬化聚合物之剩餘區域，以產生該最後顯示器。
在本製程之另一變型中，使用一「固態」不發黏黏著劑，黏附該彩色濾光片陣列至該前板疊層(「不發黏」表示在室溫或約21℃下是不發黏的)。此黏著劑可以被放置在該前板疊層上或在彩色濾光片陣列上，以及在其它部件之安裝前，可以方便地將該黏著層塗佈至一脫模片上且立刻疊合至該前板疊層或彩色濾光片陣列。較佳地在該黏著劑中形成一圖案或某些形式之糙造，以在該前板疊層至該彩色濾光片陣列之疊合期間允許空氣逸出。在使用高溫、高壓及高真空中之任何一個或多個來疊合該前板疊層與該彩色濾光片陣列前，該不發黏黏著劑允許該前板疊層與該彩色濾光片陣列間之相對移動，此足以使該兩個整體可以對準。在某些情況中，可以在疊合後，再加熱該疊合彩色濾光片陣列/前板疊層結合體，以充分實現該兩個部件之最後對準。
在本製程之另一變型中，可以使用一在室溫下發黏之感壓式黏著劑(PSA)做為該可流動材料。這樣的PSA之使用避免在高溫下處理之需求及其所造成之某些顯示器組件的變形的風險，但是一旦這些部件彼此接觸，卻具有只能提供該彩色濾光片陣列相對於該底板之有限移動的缺點。
在本製程之另一變型中，使用一潤滑脂膜，以耦接該前板疊層至該彩色濾光片陣列。適當的潤滑脂包括美國專利第5,275,680及5,371,619號所述之聚矽氧潤滑脂。這樣的潤滑脂係化學惰性的、在一大的溫度範圍內具有穩定特性、在室溫下具有長的使用壽命及在該疊合製程期間顯示出低的空隙形成。可以將該潤滑脂膜直接塗佈在該前板疊層或該彩色濾光片陣列上，或者可以將一預形成潤滑脂膜(例如：塗佈在一脫模片上)疊合至這些部件中之一或其它部件。然後，使該等部件在一起及準確對準。可藉由熱壓去除在該潤滑脂中所陷入之任何氣泡，該熱壓因該潤滑脂之黏性及可流動性而對潤滑脂膜係特別有效的。因為該潤滑脂甚至在該完成顯示器中係維持可流動的，所以較佳地在該前板疊層及彩色濾光片陣列之周圍分配一可硬化聚合物，及硬化此聚合物，以形成一在相對於彼此之正確位置上固定該前板疊層及彩色濾光片陣列之邊緣密封件，以做為在該顯示器之組裝中的最後步驟。如所述，可以有用地點硬化(spot cure)這樣的可硬化聚合物邊緣密封件，以在從該潤滑脂移除氣泡之操作期間相對於該底板固定該彩色濾光片陣列。
如所述，本發明使該光電層(通常是一前板疊層之形式)至底板之疊合與該彩色濾光片陣列至該光電層之疊合去關連。上述具有對在一單生產線上之單色及彩色顯示器的製造(如第5圖所述)提供一方便途徑的優點。如該圖所示，可以操作這樣的生產線：以採用前板疊層502之供應與底板504之供應，以及將它們一起疊合(以506來表示)，以產生底板/前板疊層疊層。然後，將這些疊層疊合至彩色濾光片陣列，以形成彩色顯示器(以508來表示)，或者可將一保護層疊合在該前板疊層上方，以形成單色顯示器(以510來表示)。
總之，本發明提供一對基本色彩之飽如只具有較少衝擊之彩色顯示器的改良白色狀態、提供色彩之平衝表現及較佳顯著飽和，以及當使用前或後照明時，可節省能量。
100．．．前板疊層
102．．．前基板
104．．．可透光導電層
106．．．光電層
108．．．疊合黏著層
110．．．脫模片
200．．．前板疊層
208．．．第二黏著層
300．．．第二倒置前板疊層
312．．．遮罩被膜
402．．．前板疊層
404．．．底板
406．．．基板
408．．．主動矩陣底板
410．．．對準標記
412．．．晶片接合區域
所附圖式之第1圖係本發明之製程中可使用之一前板疊層的示意剖面圖。
第2圖係相似於第1圖所示者之本發明的製程中可使用之一倒置前板疊層的示意剖面圖。
第3圖係相似於第1及2圖所示者之第2圖的倒置前板疊層之一修改形式的示意剖面圖。
第4圖係由本發明之一製程所組裝之一光電顯示器的上視圖，該上視圖係在一前板疊層至該底板之疊合後，但是在一彩色濾光片陣列之疊合前，在該製程之中間時間所獲得。
第5圖係顯示本發明之製程有助於使用相同前板疊層及底板之單色及彩色光電顯示器的製造之方式的流程圖。
100．．．前板疊層
102．．．前基板
104．．．可透光導電層
106．．．光電層
108．．．疊合黏著層
110．．．脫模片

Claims (7)

  1. 一種用以製造一彩色光電顯示器之方法，該方法包括：提供一光電次組合(100；200；300；402)，該光電次組合(100；200；300；402)包括一光電層(106)及一可透光導電層(104)；將該光電次組合(100；200；300；402)疊合至一包括複數個電極之底板(404、408)，以使該光電層(106)係配置在該底板(404、408)與該導電層(104)間；以及配置一彩色濾光片陣列於該導電層(104)上方，及使該彩色濾光片陣列與該底板(404、408)之電極對準，以形成該彩色光電顯示器，該方法之特徵在於：在將該光電次組合(100；200；300；402)疊合至該底板(404、408)之後，但是在將該彩色濾光片陣列配置在該導電層(104)上方之前，在該導電層(104)上方配置一可流動材料，其中藉由配置複數個間隙子於該導電層(104)上、配置該彩色濾光片陣列於該複數個間隙子上、引入一可硬化聚合物於該導電層(104)與該彩色濾光片陣列間及硬化該可硬化聚合物，實現該可流動材料及該彩色濾光片陣列在該導電層(104)上方之配置。
  2. 如申請專利範圍第1項之方法，進一步包括在該光電層之周圍配置一可硬化邊緣密封聚合物，但是在該邊緣密封聚合物中留下複數個空隙、硬化該邊緣密封聚合物，以形成一具有延伸穿過之複數個孔的邊緣密封件、施加 真空至該等孔中之至少一者，同時連接至少一其它孔至該可硬化聚合物之供應，藉此汲取該可硬化聚合物至該導電層(104)與該彩色濾光片陣列之間。
  3. 如申請專利範圍第1項之方法，其中該可流動材料係一在該導電層(104)上所分配之可硬化聚合物，以及在使該彩色濾光片陣列配置在該可硬化聚合物上方且對準後，硬化該可硬化聚合物，以固定該彩色濾光片陣列至該導電層(104)。
  4. 如申請專利範圍第3項之方法，其中在使該彩色濾光片陣列配置在該可硬化聚合物上方且對準後，硬化該可硬化聚合物之複數個分離部分，處理該可硬化聚合物以從其移除氣泡，以及硬化該未硬化聚合物之剩餘部分，以產生該最後顯示器。
  5. 如申請專利範圍第1項之方法，其中該光電材料包括一旋轉雙色構件或電致變色材料。
  6. 如申請專利範圍第1項之方法，其中該光電材料包括一電泳材料，其中該電泳材料包括配置在一流體中且能在電場之影響下經由該流體移動之複數個帶電粒子。
  7. 如申請專利範圍第6項之方法，其中該流體係氣態的。
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