WO1996026627A1 - Procede pour la fabrication de lampes electroluminescentes - Google Patents

Procede pour la fabrication de lampes electroluminescentes Download PDF

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Publication number
WO1996026627A1
WO1996026627A1 PCT/US1996/000176 US9600176W WO9626627A1 WO 1996026627 A1 WO1996026627 A1 WO 1996026627A1 US 9600176 W US9600176 W US 9600176W WO 9626627 A1 WO9626627 A1 WO 9626627A1
Authority
WO
WIPO (PCT)
Prior art keywords
capacitive electrode
layer
applying
ink
forming
Prior art date
Application number
PCT/US1996/000176
Other languages
English (en)
Inventor
William Charles Stevenson
Original Assignee
American International Pacific Industries Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by American International Pacific Industries Corp. filed Critical American International Pacific Industries Corp.
Priority to EP96907855A priority Critical patent/EP0882382A1/fr
Priority to AU51314/96A priority patent/AU5131496A/en
Priority to PCT/US1996/000176 priority patent/WO1996026627A1/fr
Priority to JP08525670A priority patent/JP2000504469A/ja
Publication of WO1996026627A1 publication Critical patent/WO1996026627A1/fr

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/12—Light sources with substantially two-dimensional radiating surfaces

Definitions

  • the present invention relates to electroluminescent lamps, and more particularly to a method for manufacturing water proof electroluminescent lamps which are suitable for many low-cost consumer applications.
  • EL lamp manufacturing techniques may be divided into two basic processes.
  • the first is a screen printing process in which the lamp is constructed layer by layer. More particularly, the lamp is constructed using costly electroluminescent inks, clear conductive indium tin oxide (ITO) transparent films, conductive inks compounded with a high volume of metallic silver and a water repellent electrical insulating coating containing an ultraviolet light-activated polymer.
  • ITO conductive indium tin oxide
  • the screen printing process allows intricate graphics effects to be created using relatively simple manufacturing processes.
  • screen printed EL lamps having high luminance or superior electrical characteristics tend to be costly to manufacture.
  • Typical manufacturing costs in high volume applications range from eight to thirteen cents per square inch, while minimal quality and performance standards result in savings of less than two cents per square inch.
  • the second process is the continuous lamination method. In this process, a first film which supports a foil is passed below a metering roller or blade which applies an insulating layer of ink.
  • a second transparent film that has been sputter coated with clear conductive ITO is similarly passed below a roller or blade, which applies a layer of phosphor ink.
  • the thickness of the insulating and phosphor layers must be precisely controlled, along with the phosphor grain dispersion in the phosphor layer.
  • the continuous lamination method requires very tight control over ink rheology.
  • the first and second films are laminated together to form a lamp core.
  • the film lamination requires heat and/or pressure which must be tightly controlled so that the light and electrical characteristics of the finished lamp are not affected. Additionally, since the phosphor layer is sensitive to water contamination, the finished lamp is cut into the desired size and shape, electrically terminated and encapsulated within a water impervious lamination film (such as Allied Signal's "ACLAR" CTFE) .
  • a water impervious lamination film such as Allied Signal's "ACLAR" CTFE
  • foil EL lamps which are high performance, high priced lamps typically unsuitable for graphics or other price-sensitive applications.
  • Foil EL lamps are also thicker and mechanically less flexible than screen printed EL lamps.
  • the typical cost of foil sensitive lamps is greater than thirty cents per square inch, and the lamps are typically used in military, aircraft and high-end industrial applications.
  • the present invention is directed to a method for manufacturing EL lamps which incorporates some of the processes which have been used in manufacturing flexible printed circuit boards.
  • the method of the present invention includes the following steps.
  • a metal foil is bonded to an insulating paper or plastic core stock and is die cut or chemically etched to form one or more rear capacitive electrodes.
  • the insulating paper or plastic core stock is coupled to a precisely positioned indexing system.
  • the indexing system may include sprocket holes along one or more edges of the insulating paper or plastic core stock.
  • a layer of hygrophobically compounded high dielectric strength EL phosphor ink is applied to the rear capacitive electrodes to precisely form the areas of illumination.
  • the EL phosphor ink is allowed to bleed past the edges of the rear capacitive electrodes, thereby providing insulation between the front and rear capacitive electrodes.
  • a layer of transparent or translucent conductive indium tin oxide (ITO) or tin oxide ink is applied to cover the layer of EL phosphor ink, forming a front capacitive electrode.
  • the ITO ink is allowed to bleed beyond the EL phosphor ink in order to make contact with a metal foil power conductor.
  • step five a transparent polyester film or ultraviolet activated dielectric coating is applied to the entire surface of the lamp.
  • step six metal foil power conductors are provided to the front and rear capacitive electrodes.
  • a first embodiment of an EL lamp manufactured by the method of the present invention comprises a capacitive electrode bonded to a paper core stock.
  • a layer of EL phosphor ink is printed on the capacitive electrode to precisely define the areas of illumination.
  • a layer of conductive ITO ink printed on the EL phosphor layer and is covered by an insulating layer consisting of a transparent polyester film.
  • the capacitive electrodes and phosphor ink and ITO layers are bonded to both surfaces of the paper core stock. The embodiment provides a low-cost EL lamp which emits light from both surfaces.
  • the method of the present invention provides the ability to manufacture EL lamps at a cost of less than five cents per square inch. Additionally, these low-cost EL lamps can be manufactured using existing or readily obtainable equipment.
  • Figs. 1(a) -(d) are a sequence of diagrams illustrating a method for manufacturing a low-cost EL lamp in accordance with the present invention
  • Fig. 2 is a cross-sectional view of a first exemplary EL lamp 100 constructed in accordance with the method of Figs. 1(a) -(d);
  • Fig. 3 is a top view of EL lamp 100 of Fig. 2;
  • Fig. 4 is a schematic diagram of an equivalent circuit of EL lamp 100
  • Fig. 5 is a cross-sectional view of a second exemplary EL lamp 200 constructed in accordance with the method of Figs. 1(a) -(d);
  • Fig. 6 is a top view of EL lamp 200 of Fig. 5;
  • Fig. 7 is a schematic diagram of an equivalent circuit of EL lamp 200.
  • the following exemplary discussion focuses on the manufacturing of a low-cost electroluminescent (EL) lamp.
  • the (EL) lamp produced by the method of the present invention is suitable for a variety of graphics and low-cost consumer applications.
  • a sequence of diagrams illustrating a preferred method for manufacturing a low-cost EL lamp in accordance with the present invention is shown.
  • a 0.002 inch thick metal foil is die cut or chemically etched to form one or more rear capacitive electrodes 104 which are bonded to a paper or plastic core stock 102.
  • the metal foil can also be embossed onto the paper or plastic core stock from a separate metal foil supply.
  • the typical thickness of paper or plastic core stock 102 is approximately 0.01 inch.
  • the die cutting or chemical etching may be done using any of a number of conventional techniques.
  • paper or plastic core stock 102 may be coupled to a conventional precision indexing system (not shown) , which may use sprocket holes which are provided along one or more edges of paper or plastic core stock 102.
  • a layer of EL phosphor ink 106 is applied to rear capacitive electrodes 104 to precisely form the areas of illumination.
  • EL phosphor ink layer 106 is allowed to bleed past the edges of rear capacitive electrodes 104 by approximately 0.02 inch, thereby insulating rear capacitive electrodes 104.
  • a layer of conductive ITO ink 108 is then applied to cover layer of EL phosphor ink 106, with ITO ink layer 108 also being allowed to bleed past the edges of EL phosphor ink layer 106 by approximately 0.02 inch.
  • a transparent or translucent polyester film 110 is then applied to the entire surface of the lamp. Polyester film 110 is typically 0.0005 inch thick, which provides adequate protection against contamination and possible electrical shock.
  • the metal foil may be replaced by a conductive plastic film which has been die cut to form capacitive electrodes 104.
  • EL phosphor ink 106 may be replaced by a plastic film imbued with EL phosphors.
  • conductive ITO ink 108 may be replaced by an ITO-coated transparent or translucent polyester film.
  • transparent or translucent polyester film 110 may be replaced by an ultraviolet activated dielectric coating.
  • Paper or plastic core stock 102 may be replaced with any of a variety of flexible, non-conducting materials such as thin plastic or fiberglass.
  • FIG. 2 a cross-sectional view of a first exemplary EL lamp 100 constructed in accordance with the above method is shown.
  • Lamp 100 includes paper or plastic core stock 102, rear capacitive electrode 104, EL phosphor layer 106, front conductive ITO layer 108 and clear electrical insulator 110.
  • layers 106 and 108 both overlap rear capacitive electrode 104 in order to provide electrical isolation between layers 106 and 108, while allowing layer 108 to make contact with a metal foil power conductor.
  • Capacitive electrode 104 is permanently bonded to paper core stock 102 using a non-conducting bonding compound.
  • EL phosphor layer 106 provides a precise definition of the area of illumination, while avoiding any waste of the expensive phosphor ink.
  • Fig. 3 provides a top view of exemplary EL lamp 100.
  • capacitive electrode 104 and EL phosphor ink layer 106 define a rectangular area of illumination.
  • the specific shape of the area of illumination is not limited to simple rectangles, circles or polygons. Any pattern with which EL phosphor ink may be printed onto capacitive electrode 104 may define the area of illumination.
  • metal foil conductors 112 and 114 are used to provide electrical power to rear capacitive electrode 104 and front conductive ITO layer 108.
  • AC alternating current
  • the mechanical structure of EL lamp 100 provides a lighting source which is light-weight and flexible.
  • EL lamp 100 functions as a capacitor with capacitive electrode 104 as one plate and conductive ITO layer as the other plate.
  • EL phosphor ink layer 106 form the dielectric of the capacitor.
  • Lamp 200 includes paper or plastic core stock 202, rear capacitive electrode 204, EL phosphor layers 208 and 210, front conductive ITO layers 212 and 214 and clear electrical insulator 216.
  • Rear capacitive electrode 204 is permanently bonded to paper or plastic core stock 202 using a non-conducting bonding compound.
  • EL phosphor layers 208 and 210 provide a precise definition of the area of illumination, while avoiding any waste of the expensive phosphor ink.
  • Fig. 6 provides a top view of exemplary EL lamp 200. As shown in Fig.
  • rear capacitive electrode 204 and EL phosphor ink layers 208 and 210 define a pair of rectangular areas of illumination.
  • the specific shape of the areas of illumination is not limited to simple rectangles, circles or polygons. Any patterns with which EL phosphor ink may be printed onto capacitive electrode 204 may define the area of illumination.
  • metal foil conductors 206, 218 and 220 are used to provide electrical power to capacitive electrode 204 and conductive ITO layers 212 and 214.
  • an appropriate AC power source is connected to conductors 206 and 218, current flows through EL phosphor ink layer 210 to ITO layer 212, thus providing illumination of the corresponding rectangular area.
  • EL lamp 100 provides a lighting source which is light-weight and flexible.
  • EL lamp 200 functions as a pair of capacitors connected in series, with capacitive electrode 204 as the center plate and conductive ITO layers 212 and 214 as the outer plates.
  • EL phosphor ink layers 208 and 210 form the dielectric regions of the capacitors.
  • the method of present invention provides a low-cost EL lamp which provides substantial illumination. Additionally, the EL lamp produced by the method of the present invention consume low power and generate little or no heat. Further, the EL lamp produced by the method of the present invention has an essentially unlimited useful life, making regular replacement unnecessary.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Electroluminescent Light Sources (AREA)

Abstract

Ce procédé sert à fabriquer des lampes électroluminescentes (EL) à faible coût, selon plusieurs étapes. Dans la première étape, on procède à un découpage à l'emporte-pièce, à un emboutissage ou à une attaque chimique d'une feuille de métal, afin de former une ou plusieurs électrodes capacitives postérieures. Dans la deuxième étape, ces électrodes capacitives sont collées à une pièce brute de papier servant de noyau, qui est couplée à un système d'indexage positionné avec précision. Dans la troisième étape, une couche d'encre de phosphore EL est appliquée sur les électrodes capacitives pour former avec précision les zones d'éclairage. Dans la quatrième étape, une couche d'encre ITO conductrice est appliquée de façon è recouvrir la couche d'encre de phosphore EL. Ensuite, dans la cinquième étape, un film de polyester transparent ou un revêtement diélectrique activé par ultraviolets est appliqué sur toute la surface de la lampe. Enfin, dans la sixième étape, des terminaisons électriques sont formées au niveau de l'électrode capacitive postérieure et de la couche d'encre ITO conductrice._____
PCT/US1996/000176 1996-02-22 1996-02-22 Procede pour la fabrication de lampes electroluminescentes WO1996026627A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP96907855A EP0882382A1 (fr) 1996-02-22 1996-02-22 Procede pour la fabrication de lampes electroluminescentes
AU51314/96A AU5131496A (en) 1996-02-22 1996-02-22 Method for manufacturing electroluminescent lamps
PCT/US1996/000176 WO1996026627A1 (fr) 1996-02-22 1996-02-22 Procede pour la fabrication de lampes electroluminescentes
JP08525670A JP2000504469A (ja) 1996-02-22 1996-02-22 放電発光ランプの製造方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1996/000176 WO1996026627A1 (fr) 1996-02-22 1996-02-22 Procede pour la fabrication de lampes electroluminescentes

Publications (1)

Publication Number Publication Date
WO1996026627A1 true WO1996026627A1 (fr) 1996-08-29

Family

ID=22254588

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1996/000176 WO1996026627A1 (fr) 1996-02-22 1996-02-22 Procede pour la fabrication de lampes electroluminescentes

Country Status (4)

Country Link
EP (1) EP0882382A1 (fr)
JP (1) JP2000504469A (fr)
AU (1) AU5131496A (fr)
WO (1) WO1996026627A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996041501A1 (fr) * 1995-06-07 1996-12-19 American International Pacific Industries Corp. Procede de fabrication de systemes de lampes electroluminescentes

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1043554A (en) * 1962-04-20 1966-09-21 Gen Electric Eletroluminescent device and electrode therefor
GB1107842A (en) * 1964-05-04 1968-03-27 Sylvania Electric Prod Process for the manufacture of electroluminescent lamps
US4534743A (en) * 1983-08-31 1985-08-13 Timex Corporation Process for making an electroluminescent lamp
EP0691798A2 (fr) * 1994-07-05 1996-01-10 Ford Motor Company Lampe fluorescente électroluminescente

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1043554A (en) * 1962-04-20 1966-09-21 Gen Electric Eletroluminescent device and electrode therefor
GB1107842A (en) * 1964-05-04 1968-03-27 Sylvania Electric Prod Process for the manufacture of electroluminescent lamps
US4534743A (en) * 1983-08-31 1985-08-13 Timex Corporation Process for making an electroluminescent lamp
EP0691798A2 (fr) * 1994-07-05 1996-01-10 Ford Motor Company Lampe fluorescente électroluminescente

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996041501A1 (fr) * 1995-06-07 1996-12-19 American International Pacific Industries Corp. Procede de fabrication de systemes de lampes electroluminescentes

Also Published As

Publication number Publication date
JP2000504469A (ja) 2000-04-11
AU5131496A (en) 1996-09-11
EP0882382A1 (fr) 1998-12-09

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