TWI670556B - 用於電光顯示器的底板 - Google Patents

用於電光顯示器的底板 Download PDF

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TWI670556B
TWI670556B TW107110515A TW107110515A TWI670556B TW I670556 B TWI670556 B TW I670556B TW 107110515 A TW107110515 A TW 107110515A TW 107110515 A TW107110515 A TW 107110515A TW I670556 B TWI670556 B TW I670556B
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substrate
electro
electrode
bottom plate
liquid
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TW201841039A (zh
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傑威廉 安塞斯
理查Ｊ 小鮑里尼
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美商電子墨水股份有限公司
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    • 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
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    • 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
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    • G09G3/3433—Control arrangements or circuits, of interest only in connection with visual indicators other than cathode-ray tubes for presentation of an assembly of a number of characters, e.g. a page, by composing the assembly by combination of individual elements arranged in a matrix no fixed position being assigned to or needed to be assigned to the individual characters or partial characters by control of light from an independent source using light modulating elements actuated by an electric field and being other than liquid crystal devices and electrochromic devices
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Abstract

一種用於一電光顯示器的底板，包括一電極及一基板。該基板對於例如水的液體可以是能滲透的，並且可以由纖維素或一類似的親水性聚合物形成。所期望的是，該電極對於與該基板相同的液體也是能滲透的，使得該等電極不會在該基板上形成不透液體的區域。例如，當該液體是水(或水溶液)時，該等電極可以由一親水性碳黑形成，其可以被塗覆至該基板上或網版印刷至該基板上。

Description

用於電光顯示器的底板 【相關申請案】
本案係基於2017年3月28日提出申請之美國臨時申請案No.62/477,505之優先權，其所有內容以參照的方式併入於此。
本發明係有關一種用於電光顯示器的底板，尤其是用於電泳顯示器的底板。
本發明提供一種用於電光顯示器的底板，該底板包含設置在基板上的至少一個電極，該基板對液體是能滲透的。該基板可以對水是能滲透的，並且可以由例如纖維素或類似的親水性聚合物形成。
在本發明之底板中，所期望的是，該等電極係為對於與該基板相同的液體也是能滲透的類型，使得該等電極不會在該基板上形成不透液體的區域。例如，當液體是水(或水溶液)時，該等電極可以由親水性碳黑形成，其可以被塗覆至基板上或網版印刷至基板上。
本發明也提供一種電光顯示器，包含一電光材料層及一底板，該電光材料層係包括包含一液體的一連續相，該底板包含與該電光材料層接觸的至少一個(底板)電極以及對該液體是能滲透的一基板。該電光材料可以是電泳材料，其包含設置在流體中並且能夠在電場的影響下移動通過流體的複數個帶電粒子。帶電粒子及流體可以被限制在複數個膠囊或微胞內。選擇性地，帶電粒子及流體可以作為由包含聚合物材料之連續相所圍繞的複數個離散微滴而存在。
本發明之電光顯示器可以更包含與來自該底板電極的電光材料層之相對側接觸的至少一個(前)電極，以及也可以包含配置成支撐該前電極的一前基板。選擇性地，該顯示器可以包含無前電極的前基板。底板及前電極中之至少一者(典型為後者)應該是透光的(此處所使用的用語是指該層透射足夠的光以使觀看者能夠透過該層觀看該電光介質的顯示狀態之變化)，並且如果該前電極是透光的，則任何存在的前基板也應該是透光的。
本發明也提供一種用於形成一電光顯示器的第一方法，該方法包含：提供一前基板；在該前基板上形成包含一液體的一電光材料層；使該層的暴露表面與一底板接觸，該底板包含設置在一基板上的至少一個電極，該基板對該液體是能滲透的；及 之後使包含該前基板、該電光材料層及該底板的組合組件經受有效引起該液體擴散通過該多孔性基板並且從該組合組件移除的條件，藉此使該電光材料層形成將該前基板及該底板彼此固定的一連貫層。
本發明也提供一種用於形成一電光顯示器的第二方法，該方法包含：提供其中具有複數個腔室的一前基板；將一電光材料設置在該等腔室內；在該等腔室內的電光材料上形成密封材料之層，該密封材料包含一液體；使該密封材料的暴露表面與一底板接觸，該底板包含設置在一基板上的至少一個電極，該基板對該液體是能滲透的；及之後使包含該前基板、該電光材料、該密封材料及該底板的組合組件經受有效引起該液體擴散通過該多孔性基板並且從該組合組件移除的條件，藉此使該密封材料之層形成將該前基板及該底板彼此固定的一連貫層。
本發明之第一及第二方法可以包括：在移除該液體之後的切割該底板基板及電極以形成複數個離散電極的附加步驟。
100‧‧‧狹縫式塗覆設備
102‧‧‧塗覆模具
104‧‧‧膠囊
106‧‧‧接合劑黏合劑
108‧‧‧基板
120‧‧‧多孔性電極
122‧‧‧多孔性基板
302‧‧‧塗覆站
304‧‧‧塗層
320‧‧‧多孔性底板
322‧‧‧滾筒
324‧‧‧滾筒
326‧‧‧乾燥區
328‧‧‧滾筒
402‧‧‧微胞基板
404‧‧‧腔室
406‧‧‧儲存器
408‧‧‧珠滴
410‧‧‧刮刀
412‧‧‧儲存器
414‧‧‧珠滴
416‧‧‧多孔性底板
418‧‧‧滾筒
附圖中的第1圖是經由本發明之第一方法的第一步 驟之示意性橫截面，且顯示在前基板上形成的電光材料層。
第2圖是類似於第1圖之截面的示意性橫截面，但是顯示第一方法的第二步驟，其中底板與電光層的暴露表面接觸。
第3圖是示意性橫截面，顯示第1圖及第2圖的方法如何能夠基於滾筒對滾筒之方式進行。
第4圖是類似於第1圖及第2圖之截面的示意性橫截面，但顯示本發明之第二方法的第一步驟，其中電光材料被填充至基板中的腔室內並施加密封材料。
第5圖是類似於第3圖之截面的示意性橫截面，但顯示本發明之第二方法的第二步驟，其中底板與密封材料的暴露表面接觸。
如上所指出，本發明提供一種用於電光顯示器的底板，該底板包含設置在基板上的至少一個電極，該基板對液體是能滲透的，以及提供包含此種底板的電光顯示器及用於製造此種顯示器之方法。
本發明係設計以解決或緩解在製造固體電光顯示器中長期遇到的某些問題，此處所使用的用語是指其中電光材料是固體的顯示器，意思是說它具有堅固的外表面，儘管該材料可能且經常具有內部液體或氣體填充的空間。因此，用語「固體電光顯示器」包括旋轉雙色構件顯示器、膠囊式電泳顯示器、微胞電泳顯示器及膠囊式液晶顯示器。
關於此種固體電光顯示器及其製造方法有大量文獻。例如，旋轉雙色構件型顯示器在美國專利號5,808,783；5,777,782；5,760,761；6,054,071；6,055,091；6,097,531；6,128,124；6,137,467；及6,147,791(儘管此種類型的顯示器通常被稱為「旋轉雙色球」顯示器，但是由於在前述提及的一些專利中，旋轉構件不是球形的，用語「旋轉雙色構件」是更為準確的)。此種顯示器使用大量小型物體(典型為球形或圓柱形)，其具有兩個以上具有不同光學特性的部分及內部偶極。這些物體懸浮在基質內液體填充的空泡內，空泡係以液體填充，使得物體自由旋轉。藉由對顯示器施加電場，因而將物體旋轉至各種位置並改變物體經由觀看表面被看到的部分，藉此改變顯示器的外觀。
Hayes,R.A.等人之「以電濕潤為基礎之錄影速度電子紙(Video-Speed Electronic Paper Based on Electrowetting)」，Nature雜誌，425期，383-385頁(2003)以及美國專利號7,420,549，係敘述了一種電濕潤顯示器。
許多讓渡或屬於美國麻省理工學院(Massachusetts Institute of Technology,MIT)、電子墨水公司(E Ink Corporation)、電子墨水加利福尼亞有限責任公司(E Ink California,LLC)及其相關公司名下的專利及專利申請案係敘述了膠囊式及微胞電泳及其他電光介質。膠囊式電泳介質包含許多小膠囊，每一小膠囊本身包括含有在流體介質中的電泳移動粒子的內相及圍繞該 內相的膠囊壁。典型地，膠囊自身係容納在聚合黏合劑(polymeric binder)內，以形成位於兩個電極之間的連貫層。典型地，該等電極中之一者是透光的，亦即，該電極透射足夠的光以使觀看者透過電極觀看電光介質的顯示狀態之變化。在微胞電泳顯示器中，帶電粒子及流體不被膠囊式在微膠囊內，而是保持在載體介質內形成的複數個腔室內，該載體介質之典型為聚合物膜。這些專利及專利申請案中敘述之技術係包含：(a)電泳粒子、流體及流體添加劑；參見例如美國專利號7,002,728及7,679,814；(b)膠囊、黏合劑及膠囊式製程；參見例如美國專利6,922,276及7,411,719；(c)微胞結構、壁材料、以及形成微胞之方法；參見例如美國專利號7,072,095及9,279,906；(d)用於填充及密封微胞之方法；參見例如美國專利號7,144,942及7,715,088；(e)含有電光材料的薄膜及次組件；參見例如美國專利號6,825,829；6,982,178；7,112,114；7,158,282；7,236,292；7,443,571；7,513,813；7,561,324；7,636,191；7,649,666；7,728,811；7,729,039；7,791,782；7,839,564；7,843,621；7,843,624；8,034,209；8,068,272；8,077,381；8,177,942；8,390,301；8,482,835；8,786,929；8,830,553；8,854,721；9,075,280；及9,238,340；及美國專利申請公開號2007/0237962； 2009/0109519；2009/0168067；2011/0164301；2014/0115884；及2014/0340738；(f)使用於顯示器中的底板、黏著層及其他輔助層與方法；參見例如美國專利D485,294；6,124,851；6,130,773；6,177,921；6,232,950；6,252,564；6,312,304；6,312,971；6,376,828；6,392,786；6,413,790；6,422,687；6,445,374；6,480,182；6,498,114；6,506,438；6,518,949；6,521,489；6,535,197；6,545,291；6,639,578；6,657,772；6,664,944；6,680,725；6,683,333；6,724,519；6,750,473；6,816,147；6,819,471；6,825,068；6,831,769；6,842,167；6,842,279；6,842,657；6,865,010；6,873,452；6,909,532；6,967,640；6,980,196；7,012,735；7,030,412；7,075,703；7,106,296；7,110,163；7,116,318；7,148,128；7,167,155；7,173,752；7,176,880；7,190,008；7,206,119；7,223,672；7,230,751；7,256,766；7,259,744；7,280,094；7,301,693；7,304,780；7,327,511；7,347,957；7,349,148；7,352,353；7,365,394；7,365,733；7,382,363；7,388,572；7,401,758；7,442,587；7,492,497；7,535,624；7,551,346；7,554,712；7,583,427；7,598,173；7,605,799；7,636,191；7,649,674；7,667,886；7,672,040；7,688,497；7,733,335；7,785,988；7,830,592；7,843,626；7,859,637； 7,880,958；7,893,435；7,898,717；7,905,977；7,957,053；7,986,450；8,009,344；8,027,081；8,049,947；8,072,675；8,077,141；8,089,453；8,120,836；8,159,636；8,208,193；8,237,892；8,238,021；8,362,488；8,373,211；8,389,381；8,395,836；8,437,069；8,441,414；8,456,589；8,498,042；8,514,168；8,547,628；8,576,162；8,610,988；8,714,780；8,728,266；8,743,077；8,754,859；8,797,258；8,797,633；8,797,636；8,830,560；8,891,155；8,969,886；9,147,364；9,025,234；9,025,238；9,030,374；9,140,952；9,152,003；9,152,004；9,201,279；9,223,164；9,285,648；及9,310,661；及美國專利申請公開號2002/0060321；2004/0008179；2004/0085619；2004/0105036；2004/0112525；2005/0122306；2005/0122563；2006/0215106；2006/0255322；2007/0052757；2007/0097489；2007/0109219；2008/0061300；2008/0149271；2009/0122389；2009/0315044；2010/0177396；2011/0140744；2011/0187683；2011/0187689；2011/0292319；2013/0250397；2013/0278900；2014/0078024；2014/0139501；2014/0192000；2014/0210701；2014/0300837；2014/0368753；2014/0376164；2015/0171112；2015/0205178；2015/0226986；2015/0227018；2015/0228666；2015/0261057； 2015/0356927；2015/0378235；2016/077375；2016/0103380；及2016/0187759；及國際申請公開號WO 00/38000；歐洲專利號1,099,207 B1及1,145,072 B1；(g)顏色形成及顏色調整；參見例如美國專利號7,075,502及7,839,564；(h)用於驅動顯示器的方法；參見例如美國專利號7,012,600及7,453,445；(i)顯示器之應用；參見例如美國專利號7,312,784及8,009,348；及(j)非電泳顯示器，如美國專利號6,241,921及美國專利申請公開號2015/0277160中所述；以及除了顯示器之外的膠囊式及微胞技術的應用；參見例如美國專利號7,615,325；及美國專利申請公開號2015/0005720及2016/0012710。
許多前述提及的專利及專利申請案意識到在膠囊式電泳介質中圍繞離散微膠囊周圍的壁可被連續相取代，因此製成所謂的聚合物分散型電泳顯示器，其中電泳介質包含複數個電泳流體的離散微滴及聚合物材料的連續相，且此種聚合物分散型電泳顯示器內之電泳流體的離散微滴即使沒有與每個個別微滴相關聯的離散膠囊膜，仍可以被視為是膠囊或微膠囊；參見例如前述提及的美國專利號6,866,760。因此，為了本申請案之目的，此種聚合物分散型電泳介質被視為是膠囊式電泳介質的子種類。
電光顯示器通常包含電光材料層及設置在電光材料之相對側上的至少兩個其他層，這兩個層中之一者是電極層。在大多數此種顯示器中，兩個層都是電極層，並且該等電極層中之一者或兩者被圖案化以限定顯示器的像素。例如，一個電極層可以被圖案化為長狀的行(row)電極，而另一個電極層被圖案化成與行電極呈直角延伸的長狀的列(column)電極，這些像素係由行電極及列電極的交叉點來限定。選擇性地，且更通常地，一個電極層具有單個連續電極之形式並且另一個電極層被圖案化為像素電極矩陣，每個像素電極限定顯示器的一個像素。在意欲與觸控筆、列印頭或是與顯示器分離的類似可移動電極一起使用的另一種類型的電光顯示器中，與電光層相鄰的層中僅有一層包含電極，該電光層之相對側上的層典型地是意欲防止可移動電極損壞該電光層之保護層。
使用數個不同的方法來製造此種三層結構。例如，在美國專利號6,839,158及6,982,178以及上述專利及專利申請案中的數個其他專利中，敘述一種方法，其中將包含可流動黏合劑中之膠囊的膠囊式電泳介質塗覆至包含氧化銦錫(ITO)的一可撓基板上，或是在塑膠膜上之類似的導電塗層(其充當最終顯示器的一個電極)，膠囊/黏合劑塗層被乾燥以從黏合劑移除液體(典型為水)，並且形成將電泳介質牢固地黏合至基板的連貫層。單獨地製備含有像素電極陣列及適合的導體配置之底板，該導體配置將像素電極連接至驅動電路。為了形成 最終顯示器，使用積層黏著劑將其上具有膠囊/黏合劑層的基板積層至底板上。(藉由用觸控筆或其他可移動電極可以在其上滑動之諸如塑膠膜的簡單保護層來替換底板，可以使用非常類似的方法來製備可與觸控筆或類似的可移動電極一起使用的電泳顯示器。)在此種方法的一個較佳形式，底板自身是可撓性的，並且藉由在塑膠膜或其他可撓性基板上印刷像素電極及導體來製備。藉由此方法大量製造顯示器之明顯的積層技術是使用積層黏著劑的滾筒積層(roll lamination)。
美國專利號6,866,760及7,079,305敘述一種用於形成聚合物分散型電泳顯示器的類似方法。在此情況下，使用水性黏合劑中的內相(電泳粒子加上分散介質)之乳液來形成初始塗層。如前述已經敘述將黏合劑乾燥，永久地膠囊式內相並且形成連貫層。
在美國專利號7,561,324中敘述該方法的變型例，其敘述所謂的「雙重脫模片」，其基本上是前述美國專利號6,982,178之前平面積層體(front plane laminate)的簡化形式。一種形式的雙重脫模片係包括：夾在兩個黏著層之間的固體電光介質層，該等黏著層中之一者或兩者被脫模片覆蓋。另一種形式的雙重脫模片係包括：夾在兩個脫模片之間的固體電光介質層。兩種形式的雙重脫模片係使用於通常類似於已敘述過的前平面積層體但涉及兩個單獨的積層板之方法；典型地，在第一積層中，將雙重脫模片積層至前電極以形成前次組件(sub-assembly)，且接著在第二積層中，將前次組件積 層至底板以形成最終顯示器，但視情況所需，這兩個積層之順序可以是顛倒的。(當使用沒有黏著層的雙重脫模片之形式時，必須在面向電光介質的前次組件或底板之表面上，提供必要的黏著層。)
美國專利號7,839,564中敘述該方法的另一變型例；該變型使用所謂的「倒置的前平面積層體」，亦即上述前平面積層體的變型例。此倒置的前平面積層體依序地包括：透光保護層及透光導電層中之至少一者；黏著層；固體電光介質層；及一脫模片。此倒置的前平面積層體用於形成電光顯示器，在電光層與前電極或前基板之間具有積層黏著層；在電光層及底板之間可以存在或不存在第二個典型是薄的黏著層。此種電光顯示器可以將良好的解析度與良好的低溫性能相結合。
微胞顯示器係以稍微不同的方式來製造。首先製備基板，典型地藉由在半固體聚合物層上壓紋，該聚合物層含有開放的腔室或凹部之陣列。用電光介質填充腔室，並典型地藉由使介質流過基板並且用刮刀移除過量的介質。密封層係形成在腔室的開口上並且乾燥或是以其他方式硬化，以形成連貫的密封層。最後，將黏著層(典型地，支撐在脫模片上)積層在密封層上。在該方法的後續步驟中，移除脫模片(如果存在)並且將黏著層積層至底板上。
這些方法都會遭遇兩個問題。第一個問題是每一個都涉及至少兩個積層步驟，在某些情況下涉及三個積層步驟；至少有一個積層步驟是將黏著層附著至電 光層上，且第二步驟是將黏著層積層至底板上。這些積層步驟較慢，典型地係以0.5ft/min(大約2.5mm/sec)及200-250℉(94-121℃)的高溫下進行。依據所使用的積層條件及環境溫度及濕度而定，這些積層條件可能某種程度上以不可預測的方式影響積層膜之含水量，並且電泳顯示器及其他電光顯示器的電光特性對顯示器的含水量是高度敏感的。第二個問題是每個方法在最終顯示器的電極之間留下至少一個黏著層，且在一些情況下留下兩個積層黏著層。此積層黏著層具有與電光層自身串聯之相當大的電阻，使得電極之間的可用電壓降的絕大部分在整個積層黏著劑上「浪費」並且不可用於驅動電光層。積層黏著劑的電阻可以改變(參見例如美國專利號7,012,735，其敘述對積層黏著劑添加離子摻雜劑以減低其電阻)，但是此種摻雜涉及其自身問題，例如移動物質不期望地遷移至積層黏著層之外，並且在任何情況下，積層黏著層的電阻不能過度減小，否則在積層黏著層內的側向傳導將影響在電光顯示器上產生的影像。
已經嘗試藉由使用輻射固化黏著劑來避免上述問題，在電光層已經被塗覆及乾燥之後藉由壓輥積層方法來施加該黏著劑。然而，此方法仍然需要二次積層並且仍然在最終顯示器之電極之間留下黏著層，且因此涉及已經討論的電壓降問題。
也已經嘗試藉由使用各種塗覆方法(包括噴塗法)在導電膜上塗覆來塗覆電光層及一個電極，以避免上述問題。然而，使用噴塗法來塗覆諸如膠囊式電泳層 的許多電光層，而未在被塗覆的電光層中留下一些間隙或「針孔」，是非常困難的，並且如果隨後將電極層塗覆在含有針孔的電光層上，被塗覆的電極層將與導電膜短路，不利地影響或破壞顯示器的電光特性。而且，在乾燥的電光層上噴塗電極層不可避免地涉及用液體再次濕潤乾燥的電光層，其可能導致電光層的液體含量變化，導致前面已討論之問題。
已知提供一種膠囊式的電泳顯示器層(參見美國專利號7,110,164及9,470,950)，其具有也可用作積層黏著劑的黏合劑。此需要黏合劑，當乾燥時，黏合劑將在不超過約150℃的溫度下流動。此大幅地限制了可以使用的黏合劑之範圍，並且因此可能在尋找與電泳層的其他組成成份相容的黏合劑時造成問題。此外，使用此種黏合劑/黏著劑來形成電光顯示器之方法，係與本發明之方法非常不同。包含此種黏合劑/黏著劑的電泳層係以正常方式塗覆並且乾燥。在乾燥及冷卻之後，接著在典型是熱積層機中將與底板接觸的電泳顯示器層再加熱，以形成最終的顯示器。相反地，如同已指摘者，在本發明之第一方法中，塗覆含有黏合劑的電光層，並且當此塗層仍然潮濕時，使底板與其接觸。只有在底板定位之後，才乾燥電光層，以將底板固定至電光層。
如同已指摘者，本發明之底板包含設置在基板上的至少一個電極，該基板對液體是能滲透的。對底板為能滲透的液體應該是存在於電光材料或密封材料的連續相中之液體，而不是可能存在於電光材料內的內腔 室或微膠囊中之液體。大多數電泳材料係使用在內腔室或微膠囊內存在的內相中疏水性且典型為烴(hydrocarbon)的液體，因為此種疏水性材料具有高電阻(因此減低了顯示器的功率消耗)並且不易於電解。此種電泳材料的黏合劑或連續相典型地是含水的，且因此底板基板應該對水是能滲透的。因此可以使用各種各樣的親水性聚合物(包括纖維素及類似的多醣體)之任一者作為底板聚合物。
顯然所期望的是，底板對為液體能滲透的比例儘可能的多，因為任何非多孔性區域的存在可能導致電光材料的不均勻乾燥，其結果是對其電光特性的均勻度產生不利之影響。因此，一般應該避免在底板上存在習知的金屬電極。較佳的電極類型包含許多導電的、親水性粒子材料的小粒子，例如親水性碳黑，其中電極藉由塗覆或印刷製程形成，致使電極能滲透液體。
在本發明之電光顯示器中使用的前基板可以具有先前技術中已知的任何類型，如例如在上述提及的專利及公開申請案中所敘述。典型地，前基板將包含在聚合物膜，例如聚(對酞酸乙二酯)上的薄的透光導電層(例如，通常藉由濺鍍施加的氧化銦錫層或類似陶瓷層；可以使用導電有機聚合物、石墨烯或金屬微絲來代替陶瓷)，儘管在一些情況下，例如在意欲用觸控筆或類似裝置書寫的顯示器中，可以省略導電層。可以以先前技術中已知的任何方式，將電光層塗覆至前基板上。而且，只要密封材料係與底板中使用的電極及基板材料相容， 任何已知的密封材料都可以用於本發明之顯示器中。
塗覆在前基板上的膠囊式電泳材料層之暴露表面通常是非平面的，因為單獨的膠囊傾向於突出到黏合劑的表面之上，並且在電泳顯示器先前技術中，黏著劑或其他層係與電泳材料層接觸，用於使電泳材料的表面被平面化。此方法中使用的底板可以實現此種平面化，但應注意確保底板以足夠的壓力施加至電泳材料層，以確保電泳材料層被平面化並且其所有部分與底板接觸，因為在兩層之間的任何空隙，可能會對顯示器的電光性能產生不利影響。
在本發明之方法中，從電光材料或密封材料中移除液體原則上係以與先前技術相同的方式進行。然而，考量到液體擴散通過底板基板之需求，可能需要稍微調整用於液體移除的條件(例如，藉由使用更長的乾燥時間及/或更高的乾燥溫度)。當然，也必須確保用於乾燥步驟的條件係與用於形成底板之電極及基板的材料是相容的，以使避免例如在乾燥步驟之期間，電極或基板材料的氧化。必要時，乾燥步驟可以在惰性氣體中進行以避免此種氧化。
現在將參照附圖來敘述本發明之較佳實施例，但僅作為說明之用。
附圖的第1圖，經由本發明之第一方法的第一步驟的示意性橫截面，係顯示藉由狹縫式塗覆設備(總體表示為100)將膠囊式(encapsulated)的電泳介質沉積在基板108上。設備100包括塗覆模具102，膠囊104及 黏合劑106的混合物經由該塗覆模具被塗覆在基板108上，基板相對於模具102如箭頭所示從右向左移動，如第1圖所示。如在先前技術之方法中，基板108包含聚合物膜，在其上表面(如第1圖所示)上承載導電層，但為了便於說明，在第1圖中未單獨顯示此導電層。膠囊104及黏合劑106沉積在基板108的導電層上，以在基板108上形成實質均勻的連貫層。
第2圖顯示將多孔性底板施加於第2圖中製造的塗覆基板。如第2圖中可見，多孔性底板係包含：較佳由親水性碳黑形成的連續多孔性電極120(選擇性地，可以提供數個離散電極)，以及較佳由纖維素形成的多孔性基板122。多孔性底板120、122在壓力下被積層至黏合劑/膠囊層104、106的暴露表面上。接著，將組合組件加熱至約60℃足以使黏合劑106中存在之相當比例的水擴散通過底板120、122並且從其暴露表面蒸發的一段時間，藉此乾燥黏合劑106以及將底板牢固地黏合至黏合劑/膠囊層及前基板上，以形成本發明之完成的顯示器。
因為多孔性電極120在整個顯示器上是連續的，因此形成的顯示器只包含單個像素。然而，如第2圖中的虛線所示，基板122及電極120之後可以被切割成數個片，以形成多像素顯示器；切割可以藉由雷射輕觸切斷或其他適當的技術來實現。接著，可以例如以美國專利號6,232,950中所敘述的方式將連接器提供給因此形成的複數個離散電極。
對於熟習製造電光顯示器之人士而言顯而易見的是，以上參照第1圖及第2圖敘述的方法可以容易地組合成連續的滾筒對滾筒操作，並且此種操作在第3圖中示意性地顯示。如第3圖所示，從滾筒(未顯示)取出之前基板108的薄片(web)在塗覆站302下方通過，其將膠囊/黏合劑塗層304沉積至基板108上。當仍然潮濕時，塗層304與多孔性底板320之連續薄片接觸，且接著立即地通過在兩個滾筒322、324之間的夾縫，以將多孔性底板320固定至塗層304。因此製造的基板/塗層/底板組件通過乾燥區326並且捲繞在滾筒328上。顯然地，視情況所需，可以在乾燥區326及滾筒328之間進行附加的操作(例如雷射切割以從底板電極形成離散電極，並且將導體提供給因此製造的離散電極)。選擇性地，從乾燥區326出現的顯示器之連續薄片可以藉由適合的切割裝置(未顯示)切斷，以形成分離的顯示器，並且滾筒328係以用於分離顯示器的適合堆疊裝置來替換。
第4圖示意性地顯示用電泳內相填充微胞。針對於微胞之形成、填充及密封的背景資訊，讀者可參考美國專利號7,715,088及9,346,987。在第4圖中，其中形成有複數個腔室404的微胞基板402如圖所示從左向右移動，如箭頭所示。來自儲存器406的內相向下流動並且在基板402的表面上形成珠滴408。藉由刮刀410移除過量的內相，以與分隔這些腔室的壁之頂部完全齊平的方式填滿腔室404。
接著，將第4圖中製造的填充基板傳送至第5圖所示的密封站，其中基板如圖所示再次地從左向右移動，如箭頭所示。來自容器412的可流動密封材料在填充基板的表面上形成珠滴414。並非如同在前述的美國專利號7,715,088中用刮刀移除過量的密封材料，而是用密封材料塗覆的填充基板立即地與多孔性底板416接觸，並且填充基板、密封材料及底板的薄片通過滾筒418的下方，滾筒用於控制密封材料層的厚度。接著，可以如上述參照第3圖所述使薄片通過乾燥站，且接著捲繞成薄片形式或切斷，以形成如前所述之單獨的顯示器。
由前述可以看出，本發明可以提供一種電光顯示器，其中在電極之間不需要黏著劑，因此使得電極之間的整個電位差可以用於驅動電光介質。本發明也消除或減低在製造電光顯示器期間對慢速積層步驟之需要。
對於熟習此技藝之人士顯而易見的是，在不脫離本發明之範圍的情況下，可以對上述本發明之特定實施例進行許多改變及修改。因此，前面敘述之整體將被解釋為說明性的而不是限制性的意義。

Claims (20)

  1. 一種電光顯示器，包含：一前電極，該前電極係透光的；設置成與該前電極相鄰的一電光材料層，該電光材料係包括包含一液體的一連續相；及設置成與該電光材料相鄰且與該前電極相對的一底板，該底板包含一底板電極及一底板基板，其中該底板電極係與該電光材料層接觸，且該底板基板對該液體是能滲透的，其中該底板電極對該液體是能滲透的。
  2. 如請求項1之電光顯示器，其中該電光材料包含設置在一流體中且能夠在一電場的影響下移動通過該流體的帶電粒子。
  3. 如請求項2之電光顯示器，其中該等帶電粒子及該流體被限制在複數個膠囊或微胞內。
  4. 如請求項2之電光顯示器，其中該等帶電粒子及該流體可以作為由包含一聚合物材料的一連續相所圍繞的複數個離散微滴而存在。
  5. 如請求項1之電光顯示器，更包含：配置成支撐該前電極的一前基板。
  6. 如請求項1之電光顯示器，其中該底板基板包含一多孔性親水性聚合物。
  7. 如請求項1或6之電光顯示器，其中該底板電極包含碳黑。
  8. 如請求項7之電光顯示器，其中該底板電極被塗覆至該底板基板上或網版印刷至該底板基板上。
  9. 一種用於形成一電光顯示器的方法，該方法包含：提供一前基板；在該前基板上形成包含一液體的一電光材料層；使該層的暴露表面與一底板接觸，該底板包含設置在一底板基板上的至少一個底板電極，該底板基板對該液體是能滲透的，其中該底板電極對該液體是能滲透的；及之後使包含該前基板、該電光材料層及該底板的組合組件經受有效引起該液體擴散通過該底板基板並且從該組合組件移除的條件，藉此使該電光材料層形成將該前基板及該底板彼此固定的一連貫層。
  10. 如請求項9之方法，更包含：移除一部分的該液體，並且切割該底板基板及該底板電極，以形成複數個離散電極。
  11. 如請求項10之方法，其中該底板基板及該底板電極係用一雷射切割。
  12. 如請求項9之方法，其中該底板基板包含一多孔性親水性聚合物。
  13. 如請求項9或12之方法，其中該底板電極包含碳黑。
  14. 如請求項13之方法，其中該底板電極被塗覆至該底板基板上或網版印刷至該底板基板上。
  15. 一種用於形成一電光顯示器的方法，該方法包含：提供其中具有複數個腔室的一前基板；將一電光材料設置在該等腔室內；在該等腔室內的電光材料上形成密封材料之層，該密封材料包含一液體；使該密封材料的暴露表面與一底板接觸，該底板包含設置在一底板基板上的至少一個底板電極，該底板基板對該液體是能滲透的，其中該底板電極對該液體是能滲透的；及之後使包含該前基板、該電光材料、該密封材料及該底板的組合組件經受有效引起該液體擴散通過該底板基板並且從該組合組件移除的條件，藉此使該密封材料之層形成將該前基板及該底板彼此固定的一連貫層。
  16. 如請求項15之方法，更包含：移除一部分的該液體，並且切割該底板基板及該底板電極，以形成複數個離散電極。
  17. 如請求項16之方法，其中該底板基板及該底板電極係用一雷射切割。
  18. 如請求項15之方法，其中該底板基板包含一多孔性親水性聚合物。
  19. 如請求項15或18之方法，其中該底板電極包含碳黑。
  20. 如請求項19之方法，其中該底板電極被塗覆至該底板基板上或網版印刷至該底板基板上。
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