WO2006033863A1 - Large area el lamp - Google Patents

Large area el lamp Download PDF

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Publication number
WO2006033863A1
WO2006033863A1 PCT/US2005/032192 US2005032192W WO2006033863A1 WO 2006033863 A1 WO2006033863 A1 WO 2006033863A1 US 2005032192 W US2005032192 W US 2005032192W WO 2006033863 A1 WO2006033863 A1 WO 2006033863A1
Authority
WO
WIPO (PCT)
Prior art keywords
lamp
lamps
panel
margin
edge
Prior art date
Application number
PCT/US2005/032192
Other languages
French (fr)
Other versions
WO2006033863B1 (en
Inventor
Anne Marie Cooper
David G. Pires
Original Assignee
World Properties, Inc.
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 World Properties, Inc. filed Critical World Properties, Inc.
Priority to EP05797888A priority Critical patent/EP1802913A4/en
Priority to JP2007532384A priority patent/JP2008513958A/en
Publication of WO2006033863A1 publication Critical patent/WO2006033863A1/en
Publication of WO2006033863B1 publication Critical patent/WO2006033863B1/en

Links

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
    • H05B33/12—Light sources with substantially two-dimensional radiating surfaces
    • H05B33/26—Light sources with substantially two-dimensional radiating surfaces characterised by the composition or arrangement of the conductive material used as an electrode
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S4/00—Lighting devices or systems using a string or strip of light sources
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H10K50/805—Electrodes
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/80—Constructional details
    • H10K59/84—Parallel electrical configurations of multiple OLEDs
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/10—OLED displays
    • H10K59/18—Tiled displays

Definitions

  • an EL “panel” is a single substrate including one or more luminous areas, wherein each luminous area is an EL “lamp”.
  • An EL lamp is essentially a capacitor having a dielectric layer between two conductive electrodes, one of which is transparent. Either the dielectric layer includes a phosphor powder or there is a separate layer of phosphor powder between the dielectric layer and one electrode. The phosphor powder radiates light in the presence of a strong electric field, using very little current.
  • a modern (post-1990) EL lamp typically includes a transparent substrate of polyester (polyethylene terephthalate, PET) or polycarbonate having a thickness of about 7.0 mils (0.178 mm).
  • PET polyethylene terephthalate
  • a transparent, front electrode of indium tin oxide (ITO) is vacuum deposited onto the substrate to a thickness of 1000 A or so.
  • a phosphor layer is screen-printed over the front electrode and a dielectric layer is screen- printed over the phosphor layer.
  • a rear electrode is screen-printed over the dielectric layer.
  • a rear insulation layer may be added in the form of a screen-printed layer or a tape with an adhesive coating.
  • the inks used for screen-printing include a binder, a solvent, and a filler, wherein the filler determines the nature of the printed layer.
  • a typical solvent is dimethylacetamide (DMAC).
  • the binder is typically a fluoropolymer such as polyvinylidene fluoride/ hexafluoropropylene (PVDF/HFP), polyester, vinyl, or epoxy.
  • a phosphor layer is typically screen-printed from a slurry (ink) containing a solvent, a binder, and doped zinc sulphide phosphor particles, such as described in U.S. Patent 5,418,062 (Budd).
  • a dielectric layer is typically screen-printed from a slurry (ink) containing a solvent, a binder, and barium titanate (BaTi ⁇ 3) particles.
  • a rear (opaque) electrode is typically screen-printed from a slurry (ink) containing a solvent, a binder, and conductive particles such as silver, carbon or graphite, or mixtures thereof.
  • a bus bar of conductive ink is typically deposited on the electrodes to reduce the voltage drop across larger lamps.
  • Another object of the invention is to provide a screen printed EL lamp having an area larger than the work area of a single screen printer.
  • a further object of the invention is to provide a method for attaching one EL lamp to another.
  • the unlit margin of a first EL lamp is covered by the lit edge of a second EL lamp to provide a substantially seamless lit area.
  • the lamps are joined mechanically at least along the margin.
  • the EL lamps are connected in parallel electrically by conductive tape overlying at least a portion of the bus bars of the lamps.
  • a plurality of lamps can be joined together to provide an EL lamp substantially larger than obtainable by other means.
  • FIG. 1 is a cross-section of an EL lamp
  • FIG. 2 is an exploded view of an EL lamp
  • FIG. 3 illustrates trimming the non-luminous area from one edge of an EL lamp
  • FIG. 4 illustrates positioning a trimmed lamp next to another EL lamp
  • FIG. 5 illustrates overlapping the non-luminous edge of an EL lamp with a trimmed EL lamp
  • FlG. 6 is a cross-section illustrating applying conductive tape to the bus bars of the EL lamps in FIG. 5.
  • FIG. 1 is a cross-section of an EL panel suitable for use in the invention. The several layers are not shown in proportion or to scale.
  • Lamp 10 includes transparent substrate 11 and transparent electrode 12, typically indium tin oxide, overlying substrate 11.
  • Phosphor layer 13 overlies electrode 12 and dielectric layer 15 overlies the phosphor layer.
  • the phosphor layer and the dielectric layer can be combined into a single layer in some applications.
  • Overlying dielectric layer 15 is rear electrode 16 containing conductive particles such as silver or carbon in a resin binder.
  • FIG. 2 is an exploded view of lamp 10.
  • Substrate 11 is coated on the side facing the viewer by electrode 12, which may or may not completely cover the substrate.
  • Phosphor layer 13 is smaller in area than electrode 12 and defines the lit area of the lamp. Specifically, there is typically a small margin or border around the perimeter of phosphor layer 13 on substrate 11.
  • Dielectric layer 15 is larger in area than phosphor layer 13 and extends slightly into the margin to isolate front electrode 12 from rear electrode 16.
  • Rear electrode 16 is typically smaller in area than dielectric layer 15.
  • Bus bar 21 provides a low resistance contact to front electrode 12 and bus bar 22 provides a low resistance contact to rear electrode 16.
  • the bus bars can be located along the same edge of lamp. As illustrated in FIG.
  • the margin along the right hand edge of lamp 10 extends from dashed line 24 to right hand edge 26.
  • the margin continues around the perimeter of lamp 10.
  • the margin along one edge of a first lamp is trimmed and the margin of a second lamp overlaps the first lamp along that edge, thereby joining the lit areas of the lamps. Because an EL lamp is a diffuse light source, the trimming need not be precisely along line 24. A small gap between lit areas is not noticeable at normal viewing distances. Cutting into a lit area obviously makes the combined lit areas smaller.
  • FIGS. 3-5 The method for joining two or more lamps is illustrated in FIGS. 3-5.
  • EL lamp 31 is cut along line 33, removing margin 34 and producing the result illustrated in FIG. 4.
  • EL lamp 31 is then place over right hand margin 35 of EL lamp 32 and joined to lamp 32 with lit edge 36 on or near the lit area of lamp 32.
  • the lamps can be joined by tape, pressure sensitive adhesive, solvent adhesive, UV cured resin or other means.
  • FIG. 6 illustrates the final step in the method wherein conductive tape 61 joins the respective bus bars of the EL lamps, connecting the lamps in parallel. That is, a first strip of tape connects the rear electrodes together and a second strip of tape connects the front electrodes together.
  • the lamps could be connected anti-parallel (front to rear and rear to front) but this is not preferred. "Parallel" is intended to cover either connection.
  • the tape extends across the backs of the lamps, rather than just across the joint, to provide adequate current carrying capability for very long lamps (several lamps joined on their sides).
  • Suitable tape includes 3M ® 1170TM smooth aluminum tape or 1181TM copper foil tape, and any metallized mesh or woven metal mesh tape. Whatever tape is used must have an adhesive with z-axis conductivity; i.e., the adhesive must be conductive in a direction through its thickness.
  • the front electrode have a bus bar overlying the front electrode under the conductive tape.
  • the rear electrode also has a bus bar underlying the conductive tape. Failure to provide a bus bar or to run the tape continuously across the backs of all lamps could result in "hot spots", localized heating from too much current and too little conductivity.
  • Another lamp can be attached to the right hand side of EL lamp 31.
  • the " lamps can be added on either side to make as wide a lamp as desired. If an EL lamp had electrodes along only one side, then additional EL lamps could be attached to the remaining three sides.
  • the EL lamps to be joined can have any desired shape, although overlapping straight edges obviously simplify joining the lamps.
  • the invention thus provides a substantially seamless, large EL panel and, in particular, provides a screen printed EL lamp having an area larger than the work area of a single screen printer.
  • a method for attaching one EL lamp to another is also provided.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Electroluminescent Light Sources (AREA)

Abstract

The unlit margin (35) of a first EL lamp (32) is covered by the lit edge (36) of a second EL lamp (31) to provide a substantially seamless lit area. The lamps are joined mechanically. The EL lamps are connected in parallel electrically by conductive tape overlying at least a portion of the bus bars of the lamps. A plurality of lamps can be joined together to provide an EL lamp substantially larger than obtainable by other means.

Description

LARG E AREA EL LAM P
BACKGROUND
This invention relates to electroluminescent (EL) lamps and, in particular, to large area EL lamps. As used herein, an EL "panel" is a single substrate including one or more luminous areas, wherein each luminous area is an EL "lamp".
An EL lamp is essentially a capacitor having a dielectric layer between two conductive electrodes, one of which is transparent. Either the dielectric layer includes a phosphor powder or there is a separate layer of phosphor powder between the dielectric layer and one electrode. The phosphor powder radiates light in the presence of a strong electric field, using very little current.
A modern (post-1990) EL lamp typically includes a transparent substrate of polyester (polyethylene terephthalate, PET) or polycarbonate having a thickness of about 7.0 mils (0.178 mm). A transparent, front electrode of indium tin oxide (ITO) is vacuum deposited onto the substrate to a thickness of 1000 A or so. A phosphor layer is screen-printed over the front electrode and a dielectric layer is screen- printed over the phosphor layer. A rear electrode is screen-printed over the dielectric layer. A rear insulation layer may be added in the form of a screen-printed layer or a tape with an adhesive coating.
The inks used for screen-printing include a binder, a solvent, and a filler, wherein the filler determines the nature of the printed layer. A typical solvent is dimethylacetamide (DMAC). The binder is typically a fluoropolymer such as polyvinylidene fluoride/ hexafluoropropylene (PVDF/HFP), polyester, vinyl, or epoxy. A phosphor layer is typically screen-printed from a slurry (ink) containing a solvent, a binder, and doped zinc sulphide phosphor particles, such as described in U.S. Patent 5,418,062 (Budd). A dielectric layer is typically screen-printed from a slurry (ink) containing a solvent, a binder, and barium titanate (BaTiθ3) particles.
A rear (opaque) electrode is typically screen-printed from a slurry (ink) containing a solvent, a binder, and conductive particles such as silver, carbon or graphite, or mixtures thereof. A bus bar of conductive ink is typically deposited on the electrodes to reduce the voltage drop across larger lamps. When the solvent and binder for each layer are chemically the same or similar, there is chemical compatibility and good adhesion between adjoining layers. The respective layers are applied, e.g. by screen-printing or roll coating, and then cured or dried.
Most EL lamps are made in batches by screen-printing rather than being made continuously, e.g. by roll coating. As a result, the size of a lamp is limited to the size of the screen, typically eighteen by twenty-four inches (46 x 61 cm.). There are many applications wherein larger lamps are desired, in signage for example. What is needed is a substantially seamless, large luminous area for back lighting graphics or transparencies. "Large" is used in the sense of the EL lamp being larger than available equipment can make. Even roll coated lamps have finite width and manufacturing equipment does not scale. That is, doubling the width of a roll coated lamp is not simply a matter of doubling the width of the rolls. Uniformity of the layers becomes a significant issue as width increases, for example.
It is known in the art to provide luminous letters on a common support with the letters interconnected by cable; see for example U.S. 2,910,792 (Pfaff, Jr.). In view of the foregoing, it is therefore an object of the invention to provide a substantially seamless, large EL panel.
Another object of the invention is to provide a screen printed EL lamp having an area larger than the work area of a single screen printer.
A further object of the invention is to provide a method for attaching one EL lamp to another.
SUMMARY OF THE INVENTION
The foregoing objects are achieved in this invention in which the unlit margin of a first EL lamp is covered by the lit edge of a second EL lamp to provide a substantially seamless lit area. The lamps are joined mechanically at least along the margin. The EL lamps are connected in parallel electrically by conductive tape overlying at least a portion of the bus bars of the lamps. A plurality of lamps can be joined together to provide an EL lamp substantially larger than obtainable by other means. BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross-section of an EL lamp;
FIG. 2 is an exploded view of an EL lamp;
FIG. 3 illustrates trimming the non-luminous area from one edge of an EL lamp;
FIG. 4 illustrates positioning a trimmed lamp next to another EL lamp; FIG. 5 illustrates overlapping the non-luminous edge of an EL lamp with a trimmed EL lamp; and
FlG. 6 is a cross-section illustrating applying conductive tape to the bus bars of the EL lamps in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-section of an EL panel suitable for use in the invention. The several layers are not shown in proportion or to scale. Lamp 10 includes transparent substrate 11 and transparent electrode 12, typically indium tin oxide, overlying substrate 11. Phosphor layer 13 overlies electrode 12 and dielectric layer 15 overlies the phosphor layer. The phosphor layer and the dielectric layer can be combined into a single layer in some applications. Overlying dielectric layer 15 is rear electrode 16 containing conductive particles such as silver or carbon in a resin binder.
FIG. 2 is an exploded view of lamp 10. Substrate 11 is coated on the side facing the viewer by electrode 12, which may or may not completely cover the substrate. Phosphor layer 13 is smaller in area than electrode 12 and defines the lit area of the lamp. Specifically, there is typically a small margin or border around the perimeter of phosphor layer 13 on substrate 11. Dielectric layer 15 is larger in area than phosphor layer 13 and extends slightly into the margin to isolate front electrode 12 from rear electrode 16. Rear electrode 16 is typically smaller in area than dielectric layer 15. Bus bar 21 provides a low resistance contact to front electrode 12 and bus bar 22 provides a low resistance contact to rear electrode 16. The bus bars can be located along the same edge of lamp. As illustrated in FIG. 2, the margin along the right hand edge of lamp 10 extends from dashed line 24 to right hand edge 26. The margin continues around the perimeter of lamp 10. In accordance with one aspect of the invention, the margin along one edge of a first lamp is trimmed and the margin of a second lamp overlaps the first lamp along that edge, thereby joining the lit areas of the lamps. Because an EL lamp is a diffuse light source, the trimming need not be precisely along line 24. A small gap between lit areas is not noticeable at normal viewing distances. Cutting into a lit area obviously makes the combined lit areas smaller.
The method for joining two or more lamps is illustrated in FIGS. 3-5. In FlG. 3, EL lamp 31 is cut along line 33, removing margin 34 and producing the result illustrated in FIG. 4. EL lamp 31 is then place over right hand margin 35 of EL lamp 32 and joined to lamp 32 with lit edge 36 on or near the lit area of lamp 32. The lamps can be joined by tape, pressure sensitive adhesive, solvent adhesive, UV cured resin or other means. FIG. 6 illustrates the final step in the method wherein conductive tape 61 joins the respective bus bars of the EL lamps, connecting the lamps in parallel. That is, a first strip of tape connects the rear electrodes together and a second strip of tape connects the front electrodes together. The lamps could be connected anti-parallel (front to rear and rear to front) but this is not preferred. "Parallel" is intended to cover either connection. As indicated by reference number 62, the tape extends across the backs of the lamps, rather than just across the joint, to provide adequate current carrying capability for very long lamps (several lamps joined on their sides). Suitable tape includes 3M® 1170™ smooth aluminum tape or 1181™ copper foil tape, and any metallized mesh or woven metal mesh tape. Whatever tape is used must have an adhesive with z-axis conductivity; i.e., the adhesive must be conductive in a direction through its thickness.
Also for very long lamps, it is necessary that at least the front electrode have a bus bar overlying the front electrode under the conductive tape. Preferably, the rear electrode also has a bus bar underlying the conductive tape. Failure to provide a bus bar or to run the tape continuously across the backs of all lamps could result in "hot spots", localized heating from too much current and too little conductivity.
Another lamp can be attached to the right hand side of EL lamp 31. Actually, the "lamps can be added on either side to make as wide a lamp as desired. If an EL lamp had electrodes along only one side, then additional EL lamps could be attached to the remaining three sides. The EL lamps to be joined can have any desired shape, although overlapping straight edges obviously simplify joining the lamps.
The invention thus provides a substantially seamless, large EL panel and, in particular, provides a screen printed EL lamp having an area larger than the work area of a single screen printer. A method for attaching one EL lamp to another is also provided.
Having thus described the invention, it will be apparent to those skilled in the art that many modifications can be made with the scope of the invention.

Claims

What is claimed as the invention is:
1. An EL panel comprising: at least two EL lamps mechanically joined along overlapping edges and having conductive tape electrically connecting at least one electrode from a first lamp with an electrode of a second lamp.
2. The EL panel as set forth in claim 1 wherein said EL lamps each include an unlit margin along a first edge.
3. The EL panel as set forth in claim 2 wherein a first EL lamp has the margin removed and overlies a second EL lamp along the margin of the second EL lamp to provide a substantially seamless luminous area in said panel.
4. The EL panel as set forth in claim 1 wherein each EL lamp includes at least two electrodes and said conductive tape connects the lamps in parallel.
5. The EL panel as set forth in claim 4 wherein said EL lamps include bus bars and said conductive tape covers said bus bars.
6. The EL panel as set forth in claim 1 wherein the conductive tape extends continuously across the backs of said at least two lamps.
7. An EL panel comprising: at least two EL lamps, a first of said lamps having an unlit margin along one edge thereof and a second of said lamps having a lit area extending to an edge of said second lamp; wherein the lit edge of the second lamp overlaps the unlit margin of the first lamp and is mechanically joined to the first EL lamp; said EL lamps each including at least two electrodes and said panel further including conductive tape electrically connecting said EL lamps in parallel; whereby said first EL lamp and said second EL lamp provide a substantially seamless luminous area in said panel.
8. A method for producing a large area EL lamp, said method including the steps of: placing the edge of a first EL lamp over the unlit margin of a second EL lamp, wherein the first EL lamp is luminous to said edge; mechanically joining the first EL lamp and the second EL lamp; and connecting the EL lamps in parallel with conductive tape.
9. A method for producing a large area EL lamp as set forth in claim 8 wherein said first EL lamp and said second EL lamp include bus bars and said connecting step includes covering said bus bars with said conductive tape.
PCT/US2005/032192 2004-09-15 2005-09-08 Large area el lamp WO2006033863A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP05797888A EP1802913A4 (en) 2004-09-15 2005-09-08 Large area el lamp
JP2007532384A JP2008513958A (en) 2004-09-15 2005-09-08 Large area EL lamp

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/941,381 2004-09-15
US10/941,381 US7543954B2 (en) 2004-09-15 2004-09-15 Large area EL lamp

Publications (2)

Publication Number Publication Date
WO2006033863A1 true WO2006033863A1 (en) 2006-03-30
WO2006033863B1 WO2006033863B1 (en) 2006-06-01

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US (1) US7543954B2 (en)
EP (1) EP1802913A4 (en)
JP (1) JP2008513958A (en)
KR (1) KR20070044064A (en)
CN (1) CN101023293A (en)
WO (1) WO2006033863A1 (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102006059509B4 (en) * 2006-12-14 2012-05-03 Novaled Ag Organic light-emitting element
KR100920448B1 (en) * 2007-11-16 2009-10-08 주식회사 삼창에스씨 Lighting apparatus for bridge railing
US20100009588A1 (en) * 2008-03-03 2010-01-14 Ray Robert B Method of manufacturing lighted signs from electroluminescent panels
JP2010186609A (en) * 2009-02-11 2010-08-26 Brother Ind Ltd Organic el light-emitting device
CN113921675B (en) * 2021-11-24 2024-07-19 固安翌光科技有限公司 Stretchable linear illuminator, preparation method thereof and luminous product

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4138620A (en) * 1978-03-24 1979-02-06 Minnesota Mining And Manufacturing Company Multi-panel electroluminescent light assembly

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US2964587A (en) * 1956-11-16 1960-12-13 Otis N Minot Tape conductor
US2910792A (en) 1958-10-06 1959-11-03 Pfaff & Kendall Highway sign
US3161797A (en) * 1962-02-28 1964-12-15 Sylvania Electric Prod Electroluminescent device
US4460804A (en) * 1982-08-02 1984-07-17 Svejkovsky Roger L Flexible electrically conductive adhesive tape
JPS6229090A (en) * 1985-07-30 1987-02-07 日本精機株式会社 El panel
JPH0638394Y2 (en) * 1986-08-29 1994-10-05 日本電信電話株式会社 EL display device
US5416622A (en) * 1993-02-01 1995-05-16 Minnesota Mining And Manufacturing Company Electrical connector
JPH10208877A (en) * 1997-01-22 1998-08-07 Nec Kansai Ltd Electroluminescence lamp
JP3897944B2 (en) * 1999-10-26 2007-03-28 セイコープレシジョン株式会社 EL backlight device

Patent Citations (1)

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Publication number Priority date Publication date Assignee Title
US4138620A (en) * 1978-03-24 1979-02-06 Minnesota Mining And Manufacturing Company Multi-panel electroluminescent light assembly

Also Published As

Publication number Publication date
US20060056168A1 (en) 2006-03-16
US7543954B2 (en) 2009-06-09
JP2008513958A (en) 2008-05-01
EP1802913A4 (en) 2009-06-03
WO2006033863B1 (en) 2006-06-01
EP1802913A1 (en) 2007-07-04
CN101023293A (en) 2007-08-22
KR20070044064A (en) 2007-04-26

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