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US20050122563A1 - Electro-optic displays - Google Patents

Electro-optic displays Download PDF

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Publication number
US20050122563A1
US20050122563A1 US10/898,027 US89802704A US2005122563A1 US 20050122563 A1 US20050122563 A1 US 20050122563A1 US 89802704 A US89802704 A US 89802704A US 2005122563 A1 US2005122563 A1 US 2005122563A1
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United States
Prior art keywords
electro
lamination adhesive
front plane
plane laminate
layer
Prior art date
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Abandoned
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US10/898,027
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English (en)
Inventor
Charles Honeyman
Harit Doshi
Seungman Sohn
Eva Chen
Richard LeCain
Simon Pang
Gregg Duthaler
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E Ink Corp
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E Ink Corp
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Publication date
Application filed by E Ink Corp filed Critical E Ink Corp
Priority to US10/898,027 priority Critical patent/US20050122563A1/en
Assigned to E INK CORPORATION reassignment E INK CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DOSHI, HARIT, HONEYMAN, CHARLES H., PANG, SIMON, SOHN, SEUNGMAN, DUTHALER, GREGG M., LE CAIN, RICHARD D., CHEN, EVA
Publication of US20050122563A1 publication Critical patent/US20050122563A1/en
Priority to US11/277,368 priority patent/US7636191B2/en
Priority to US12/605,606 priority patent/US7957053B2/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B26/00—Optical devices or arrangements for the control of light using movable or deformable optical elements
    • G02B26/02—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the intensity of light
    • G—PHYSICS
    • G02—OPTICS
    • 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
    • G02F1/166—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 characterised by the electro-optical or magneto-optical effect
    • G02F1/167—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 characterised by the electro-optical or magneto-optical effect by electrophoresis
    • G—PHYSICS
    • G02—OPTICS
    • 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
    • G02F2202/00—Materials and properties
    • G02F2202/28—Adhesive materials or arrangements

Definitions

  • This invention relates to improvements in electro-optic displays. More specifically, in one aspect this invention relates to electro-optic media and displays in which the thickness of a lamination adhesive layer is controlled to avoid certain problems otherwise experienced in such displays. In another aspect, this invention relates to the prevention of void growth in electro-optic displays.
  • Electro-optic displays comprise a layer of electro-optic material, a term which is used herein in its conventional meaning in the imaging art to refer to a material having first and second display states differing in at least one optical property, the material being changed from its first to its second display state by application of an electric field to the material.
  • the optical property is typically color perceptible to the human eye, it may be another optical property, such as optical transmission, reflectance, luminescence or, in the case of displays intended for machine reading, pseudo-color in the sense of a change in reflectance of electromagnetic wavelengths outside the visible range.
  • bistable and “bistability” are used herein in their conventional meaning in the imaging art to refer to displays comprising display elements having first and second display states differing in at least one optical property, and such that after any given element has been driven, by means of an addressing pulse of finite duration, to assume either its first or second display state, after the addressing pulse has terminated, that state will persist for at least several times, for example at least four times, the minimum duration of the addressing pulse required to change the state of the display element.
  • some particle-based electrophoretic displays capable of gray scale are stable not only in their extreme black and white states but also in their intermediate gray states, and the same is true of some other types of electro-optic displays. This type of display is properly called “multi-stable” rather than bistable, although for convenience the term “bistable” may be used herein to cover both bistable and multi-stable displays.
  • electro-optic displays are known.
  • One type of electro-optic display is a rotating bichromal member type as described, for example, in U.S. Pat. Nos. 5,808,783; 5,777,782; 5,760,761; 6,054,071 6,055,091; 6,097,531; 6,128,124; 6,137,467; and 6,147,791 (although this type of display is often referred to as a “rotating bichromal ball” display, the term “rotating bichromal member” is preferred as more accurate since in some of the patents mentioned above the rotating members are not spherical).
  • Such a display uses a large number of small bodies (typically spherical or cylindrical) which have two or more sections with differing optical characteristics, and an internal dipole. These bodies are suspended within liquid-filled vacuoles within a matrix, the vacuoles being filled with liquid so that the bodies are free to rotate. The appearance of the display is changed to applying an electric field thereto, thus rotating the bodies to various positions and varying which of the sections of the bodies is seen through a viewing surface.
  • bodies typically spherical or cylindrical
  • These bodies are suspended within liquid-filled vacuoles within a matrix, the vacuoles being filled with liquid so that the bodies are free to rotate.
  • the appearance of the display is changed to applying an electric field thereto, thus rotating the bodies to various positions and varying which of the sections of the bodies is seen through a viewing surface.
  • electro-optic display uses an electrochromic medium, for example an electrochromic medium in the form of a nanochromic film comprising an electrode formed at least in part from a semi-conducting metal oxide and a plurality of dye molecules capable of reversible color change attached to the electrode; see, for example O'Regan, B., et al., Nature 1991, 353, 737; and Wood, D., Information Display, 18(3), 24 (March 2002). See also Bach, U., et al., Adv. Mater., 2002, 14(11), 845. Nanochromic films of this type are also described, for example, in U.S. Pat. No. 6,301,038, International Application Publication No. WO 01/27690, and in U.S. patent application 2003/0214695. This type of medium is also typically bistable.
  • an electrochromic medium for example an electrochromic medium in the form of a nanochromic film comprising an electrode formed at least in part from a semi-conducting metal oxide and a plurality
  • Electrophoretic display Another type of electro-optic display, which has been the subject of intense research and development for a number of years, is the particle-based electrophoretic display, in which a plurality of charged particles move through a suspending fluid under the influence of an electric field.
  • Electrophoretic displays can have attributes of good brightness and contrast, wide viewing angles, state bistability, and low power consumption when compared with liquid crystal displays. Nevertheless, problems with the long-term image quality of these displays have prevented their widespread usage. For example, particles that make up electrophoretic displays tend to settle, resulting in inadequate service-life for these displays.
  • encapsulated electrophoretic media comprise numerous small capsules, each of which itself comprises an internal phase containing electrophoretically-mobile particles suspended in a liquid suspending medium, and a capsule wall surrounding the internal phase.
  • the capsules are themselves held within a polymeric binder to form a coherent layer positioned between two electrodes. Encapsulated media of this type are described, for example, in U.S. Pat. Nos.
  • An encapsulated electrophoretic display typically does not suffer from the clustering and settling failure mode of traditional electrophoretic devices and provides further advantages, such as the ability to print or coat the display on a wide variety of flexible and rigid substrates.
  • printing is intended to include all forms of printing and coating, including, but without limitation: pre-metered coatings such as patch die coating, slot or extrusion coating, slide or cascade coating, curtain coating; roll coating such as knife over roll coating, forward and reverse roll coating; gravure coating; dip coating; spray coating; meniscus coating; spin coating; brush coating; air knife coating; silk screen printing processes; electrostatic printing processes; thermal printing processes; ink jet printing processes; and other similar techniques.
  • pre-metered coatings such as patch die coating, slot or extrusion coating, slide or cascade coating, curtain coating
  • roll coating such as knife over roll coating, forward and reverse roll coating
  • gravure coating dip coating
  • spray coating meniscus coating
  • spin coating spin coating
  • brush coating air knife coating
  • silk screen printing processes electrostatic printing processes
  • thermal printing processes
  • Known encapsulated electrophoretic displays can be divided into two main types, referred to hereinafter for convenience as “single particle” and “dual particle” respectively.
  • a single particle medium has only a single type of electrophoretic particle suspended in a colored medium, at least one optical characteristic of which differs from that of the particles. (In referring to a single type of particle, we do not imply that all particles of the type are absolutely identical.
  • the optical characteristic is typically color visible to the human eye, but may, alternatively or in addition, be any one or more of reflectivity, retroreflectivity, luminescence, fluorescence, phosphorescence, or color in the broader sense of meaning a difference in absorption or reflectance at non-visible wavelengths.
  • the medium can display the optical characteristic of the particles (when the particles are adjacent the electrode closer to the observer, hereinafter called the “front” electrode) or the optical characteristic of the suspending medium (when the particles are adjacent the electrode remote from the observer, hereinafter called the “rear” electrode, so that the particles are hidden by the colored suspending medium).
  • a dual particle medium has two different types of particles differing in at least one optical characteristic and a suspending fluid which may be uncolored or colored, but which is typically uncolored.
  • the two types of particles differ in electrophoretic mobility; this difference in mobility may be in polarity (this type may hereinafter be referred to as an “opposite charge dual particle” medium) and/or magnitude.
  • the medium can display the optical characteristic of either set of particles, although the exact manner in which this is achieved differs depending upon whether the difference in mobility is in polarity or only in magnitude. For ease of illustration, consider an electrophoretic medium in which one type of particles are black and the other type white.
  • the two types of particles differ in polarity (if, for example, the black particles are positively charged and the white particles negatively charged), the particles will be attracted to the two different electrodes, so that if, for example, the front electrode is negative relative to the rear electrode, the black particles will be attracted to the front electrode and the white particles to the rear electrode, so that the medium will appear black to the observer. Conversely, if the front electrode is positive relative to the rear electrode, the white particles will be attracted to the front electrode and the black particles to the rear electrode, so that the medium will appear white to the observer.
  • both types of particles have charges of the same polarity, but differ in electrophoretic mobility (this type of medium may hereinafter to referred to as a “same polarity dual particle” medium), both types of particles will be attracted to the same electrode, but one type will reach the electrode before the other, so that the type facing the observer differs depending upon the electrode to which the particles are attracted. For example suppose the previous illustration is modified so that both the black and white particles are positively charged, but the black particles have the higher electrophoretic mobility.
  • both the black and white particles will be attracted to the front electrode, but the black particles, because of their higher mobility, will reach it first, so that a layer of black particles will coat the front electrode and the medium will appear black to the observer.
  • both the black and white particles will be attracted to the rear electrode, but the black particles, because of their higher mobility will reach it first, so that a layer of black particles will coat the rear electrode, leaving a layer of white particles remote from the rear electrode and facing the observer, so that the medium will appear white to the observer: note that this type of dual particle medium requires that the suspending fluid to sufficiently transparent to allow the layer of white particles remote from the rear electrode to be readily visible to the observer.
  • the suspending fluid in such a display is not colored at all, but some color may be incorporated for the purpose of correcting any undesirable tint in the white particles seen therethrough.
  • Both single and dual particle electrophoretic displays may be capable of intermediate gray states having optical characteristics intermediate the two extreme optical states already described.
  • microcell electrophoretic display A related type of electrophoretic display is a so-called “microcell electrophoretic display”.
  • the charged particles and the suspending fluid are not encapsulated within capsules but instead are retained within a plurality of cavities formed within a carrier medium, typically a polymeric film.
  • a carrier medium typically a polymeric film.
  • electrophoretic media are often opaque (since, for example, in many electrophoretic media, the particles substantially block transmission of visible light through the display) and operate in a reflective mode
  • many electrophoretic displays can be made to operate in a so-called “shutter mode” in which one display state is substantially opaque and one is light-transmissive. See, for example, the aforementioned U.S. Pat. Nos. 6,130,774 and 6,172,798, and U.S. Pat. Nos. 5,872,552; 6,144,361; 6,271,823; 6,225,971; and 6,184,856.
  • Dielectrophoretic displays which are similar to electrophoretic displays but rely upon variations in electric field strength, can operate in a similar mode; see U.S. Pat. No. 4,418,346.
  • Other types of electro-optic displays may also be capable of operating in shutter mode.
  • An electro-optic display normally comprises a layer of electro-optic material and at least two other layers disposed on opposed sides of the electro-optic material, one of these two layers being an electrode layer.
  • both the layers are electrode layers, and one or both of the electrode layers are patterned to define the pixels of the display.
  • one electrode layer may be patterned into elongate row electrodes and the other into elongate column electrodes running at right angles to the row electrodes, the pixels being defined by the intersections of the row and column electrodes.
  • one electrode layer has the form of a single continuous electrode and the other electrode layer is patterned into a matrix of pixel electrodes, each of which defines one pixel of the display.
  • electro-optic display which is intended for use with a stylus, print head or similar movable electrode separate from the display
  • only one of the layers adjacent the electro-optic layer comprises an electrode, the layer on the opposed side of the electro-optic layer typically being a protective layer intended to prevent the movable electrode damaging the electro-optic layer.
  • the manufacture of a three-layer electro-optic display normally involves at least one lamination operation.
  • a process for manufacturing an encapsulated electrophoretic display in which an encapsulated electrophoretic medium comprising capsules in a binder is coated on to a flexible substrate comprising indium-tin-oxide or a similar conductive coating (which acts as an one electrode of the final display) on a plastic film, the capsules/binder coating being dried to form a coherent layer of the electrophoretic medium firmly adhered to the substrate.
  • a backplane containing an array of pixel electrodes and an appropriate arrangement of conductors to connect the pixel electrodes to drive circuitry, is prepared.
  • the substrate having the capsule/binder layer thereon is laminated to the backplane using a lamination adhesive.
  • a lamination adhesive A very similar process can be used to prepare an electrophoretic display useable with a stylus or similar movable electrode by replacing the backplane with a simple protective layer, such as a plastic film, over which the stylus or other movable electrode can slide.
  • the backplane is itself flexible and is prepared by printing the pixel electrodes and conductors on a plastic film or other flexible substrate.
  • electro-optic displays that other types of electro-optic media, for example microcell electrophoretic media and rotating bichromal member media, can be laminated in an exactly analogous manner.
  • the obvious lamination technique for mass production of displays by this process is roll lamination using a lamination adhesive.
  • the substrate having the capsule/binder layer thereon is first laminated to a layer of adhesive carried on a release sheet to form a structure called a “front plane laminate” (or “FPL”), and thereafter the release sheet is peeled from the front plane laminate and the remaining layers of the front plane laminate are laminated to a backplane using the adhesive layer exposed by removal of the release sheet, thereby forming the final display.
  • FPL front plane laminate
  • a related lamination process using two separate laminations is described in copending application Ser. No. 10/605,024, filed Sep. 2, 2003; see also the corresponding International Application PCT/US03/27686. Publication No. WO 2004/023195.
  • the lamination adhesive is located between the electrodes which apply the electric field needed to change the electrical state of the electro-optic medium, so that the electrical properties of the adhesive become crucial.
  • the volume resistivity of the lamination adhesive becomes important, since the voltage drop across the electro-optic medium is essentially equal to the voltage drop across the electrodes, minus the voltage drop across the lamination adhesive. If the resistivity of the adhesive layer is too high, a substantial voltage drop will occur within the adhesive layer, requiring an increase in voltage across the electrodes.
  • void problem To ensure a high quality display, it is essential that the final display be free from voids, since such voids produce visible defects in images written on the display. To ensure that the final display is free from voids, it is essential that both the lamination to form the front plane laminate (when effected) and the final lamination to the backplane be carried out without the formation of voids.
  • the final display be able to withstand substantial temperature changes (such as may occur, for example, when a portable computer or personal digital assistant is removed from an air-conditioned car to outdoor sun on a hot day) without inducing or aggravating the formation of voids, since it has been found that some displays, which initially appear essentially free from voids, can develop objectionable voids when exposed to such temperature changes. This phenomenon may be termed “void re-growth”.
  • this invention provides an electro-optic display having a controlled thickness of lamination adhesive.
  • the aforementioned front plane laminate comprises, in order, a polymeric film substrate, a light-transmissive electrode, a layer of a electro-optic medium, a layer of lamination adhesive and a release sheet; to produce the final display, this front laminate is laminated in the manner already described to a backplane comprising a plurality of pixel electrodes on a glass or other substrate.
  • the release sheet of the front plane laminate is removed prior to its lamination to the backplane, so that the final structure comprises, in order, the polymeric film substrate, light-transmissive electrode, layer of a electro-optic medium, layer of lamination adhesive, pixel electrodes and glass or other substrate.
  • Such a structure is in principle structurally unstable, as differences in thermal and moisture expansion coefficients of the polymeric film and glass substrates induce very large stress and strains in the display. Under particular stresses, especially those realized at elevated temperatures, the instability manifests itself in the formation of voids (i.e. delamination, hereafter called void growth) of the layers derived from the front plane laminate from the glass substrate.
  • This invention provides approaches to eliminating, or at least reducing, void growth in electro-optic displays.
  • this invention provides an electro-optic display comprising first and second substrates and a lamination adhesive layer and a layer of an electro-optic material disposed between the first and second substrates, the lamination adhesive layer having a thickness of from about 14 to about 25 ⁇ m.
  • This electro-optic display may hereinafter for convenience be referred to as the “controlled lamination adhesive thickness” or “CLAT” display of the present invention.
  • the lamination adhesive layer desirably has a thickness of from about 14 to about 20 ⁇ m.
  • the electro-optic layer comprises a particle-based electrophoretic material comprising a suspending fluid and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material.
  • an electrophoretic material may be an encapsulated electrophoretic material in which the suspending fluid and the electrically charged particles and encapsulated within a plurality of capsules, each of the capsules having a capsule wall.
  • the encapsulated electrophoretic material may be of the polymer-dispersed type with the suspending fluid and the electrically charged particles in the form of a plurality of droplets dispersed in a continuous phase which in effect acts as capsule walls for the droplets, although no discrete capsule wall for each droplet is present.
  • the lamination adhesives used in CLAT displays may be similar to those used in the aforementioned 2003/0025855.
  • the lamination adhesive may have one or more of the following characteristics:
  • This invention also provides a front plane laminate for forming an electro-optic display, the front plane laminate being an article of manufacture comprising, in order, a light-transmissive electrically-conductive layer, a layer of an electro-optic material, a lamination adhesive having a thickness of from about 14 to about 25 ⁇ m, and a release sheet.
  • the lamination adhesive layer desirably has a thickness of from about 14 to about 20 ⁇ m.
  • the electro-optic layer may comprise a particle-based electrophoretic material comprising a suspending fluid and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material.
  • Such an electrophoretic material may be an encapsulated electrophoretic material in which the suspending fluid and the electrically charged particles and encapsulated within a plurality of capsules, each of the capsules having a capsule wall.
  • This invention also provides an electro-optic display comprising: a backplane comprising at least one electrode; a layer of electro-optic material; and a lamination adhesive disposed between the backplane and the layer of electro-optic material, the lamination adhesive comprising an adhesion promoter effective to increase the adhesion between the lamination adhesive and the backplane.
  • the adhesion promoter may comprise any one or more of 1-propanamine, 3-aminopropyltrimethoxysilane, 3-aminopropyl-dimethylethoxysilane, and hexamethyldisilizane.
  • This invention also provides a front plane laminate for forming an electro-optic display, the front plane laminate being an article of manufacture comprising, in order, a front substrate, a light-transmissive electrically-conductive layer, a layer of an electro-optic material, and a lamination adhesive layer, wherein the front substrate has a thickness not greater than about 20 mil (about 0.5 mm).
  • the front substrate desirably has a thickness not greater than about 10 mil (about 0.25 mm).
  • the front plane laminate may further comprise a release sheet covering the lamination adhesive.
  • a release sheet desirably has a thickness not greater than about 15 mil (about 0.37 mm), and preferably not greater than about 10 mil (about 0.25 mm).
  • the electro-optic material may be an encapsulated electrophoretic material comprising a plurality of capsules, each capsule comprising a capsule wall, a suspending fluid encapsulated within the capsule wall and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material.
  • This invention also provides a front plane laminate for forming an electro-optic display, the front plane laminate being an article of manufacture comprising, in order, a light-transmissive electrically-conductive layer, a layer of an electro-optic material, a lamination adhesive layer, and a release sheet wherein the release sheet has a thickness not greater than about 15 mil (about 0.37 mm).
  • the electro-optic material may be an encapsulated electrophoretic material comprising a plurality of capsules, each capsule comprising a capsule wall, a suspending fluid encapsulated within the capsule wall and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material.
  • This invention also provides a front plane laminate for forming an electro-optic display, the front plane laminate being an article of manufacture comprising, in order, a light-transmissive electrically-conductive layer, a layer of an encapsulated electrophoretic material comprising a plurality of capsules, each capsule comprising a capsule wall, a suspending fluid encapsulated within the capsule wall and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material, and a lamination adhesive layer, wherein the lamination adhesive layer has a peak to valley roughness not greater than about 15 ⁇ m.
  • the lamination adhesive layer desirably has a peak to valley roughness not greater than about 10 ⁇ m, preferably not greater than about 5 ⁇ m.
  • this invention provides a front plane laminate for forming an electro-optic display, the front plane laminate being an article of manufacture comprising, in order, a light-transmissive electrically-conductive layer, a layer of an encapsulated electrophoretic material comprising a plurality of capsules, each capsule comprising a capsule wall, a suspending fluid encapsulated within the capsule wall and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material, and a lamination adhesive layer, wherein the lamination adhesive layer has local surface angles not greater than about 15° from the horizontal.
  • the lamination adhesive layer desirably has local surface angles not greater than about 100 from the horizontal, preferably not greater than about 5° from the horizontal.
  • FIG. 1A is a schematic side elevation of a electro-optic display as it is formed at room temperature.
  • FIG. 1B is a schematic side elevation similar to that of FIGS. 1A but taken at an elevated temperature and showing the buckling of the front substrate of the electro-optic display.
  • FIG. 2 is a schematic side elevation of a front plane laminate of the present invention showing the uneven surfaces of the electro-optic material and lamination adhesive layer.
  • FIG. 3 is a schematic side elevation similar to that of FIG. 2 but prior to the application of the lamination adhesive and shows the manner in which the peak-to-valley roughness and the local surface angles of the electro-optic layer are measured.
  • FIG. 4A is a photomicrograph of a front plane laminate having a peak-to-valley roughness greater than 5 ⁇ m.
  • FIG. 4B is a photomicrograph showing the voids which result from the lamination of the front plane laminate of FIG. 4A to a glass backplane.
  • the thickness of the lamination adhesive is controlled to eliminate, or at least substantially reduce, void re-growth in the final display.
  • typically a minimum lamination adhesive thickness of about 14 ⁇ m is needed to reduce void re-growth to an acceptable level, and that increasing the lamination adhesive thickness further, up to about 18 ⁇ m, may provide additional control of void re-growth.
  • Increasing the lamination adhesive thickness above about 18 ⁇ m does not appear to increase resistance to void re-growth but, as already noted, it is desirable to avoid an unnecessarily thick lamination adhesive layer in order to avoid a large voltage drop across this layer, so in practice it is advantageous to limit the lamination adhesive thickness to not more than about 25, or preferably 20, ⁇ m.
  • the lamination adhesive may be as described in the aforementioned 2003/0025855; thus, the lamination adhesive may have any one of more of the following properties:
  • the CLAT display and front plane laminate of the invention are especially, but not exclusively, intended to use with encapsulated electrophoretic media; as discussed above, such media comprise a plurality of capsules, each capsule comprising a capsule wall, a suspending fluid encapsulated within the capsule wall and a plurality of electrically charged particles suspended in the suspending fluid and capable of moving therethrough on application of an electric field to the electrophoretic material.
  • electro-optic media for example microcell electrophoretic, rotating bichromal member media, and electrochromic media, may also be used.
  • Example 1 is now given, though by way of illustration only, to show details of preferred materials and techniques for use in CLAT display of the present invention.
  • An internal phase was prepared comprising polymer-coated titania white particles and polymer-coated carbon black particles in a hydrocarbon suspending fluid.
  • This internal phase was encapsulated in gelatin/acacia microcapsules substantially as described in Paragraphs [0069] to [0074] of the aforementioned 2002/0180687.
  • the resultant microcapsules were separated by size and capsules having an average particle size of about 35 ⁇ m were used in the following experiments.
  • microcapsules were mixed into a slurry with a polyurethane binder and coated by a roll-to-roll process at a dry coating weight of 18 g m ⁇ 2 on to the surface of a 7 mil (177 ⁇ m) poly(ethylene terephthalate) film carrying an indium tin oxide (ITO) layer on one surface, the microcapsules being deposited on the ITO-covered surface, substantially as described in Paragraphs [0075] and [0076] of the aforementioned 2002/0180687.
  • ITO indium tin oxide
  • the capsule-bearing film was then formed into a front plane laminate by laminating it to a layer of a polyurethane lamination adhesive carried on a release sheet, this lamination being effected at 65 psig (0.51 mPa) at a speed of 6 inches/min (2.5 mm/sec) using a Western Magnum twin roll Laminator with both rolls held at 120° C.
  • the thickness of the lamination adhesive on the release sheet was varied to vary the thickness of the corresponding layer in the final display.
  • pieces of the resultant front plane laminate has their release sheets removed and were then laminated at 75° C. to the ITO-covered surfaces of ITO-on-glass substrates.
  • the displays thus produced were subjected to a temperature of 90° C. and a relative humidity of 17 per cent for 17 hours, and the percentage of voids in the display was measured before exposure to the elevated temperature, after 5 hours exposure and after the 17 hours exposure.
  • Eight sections of each display was measured and the results reported below are the average of the eight sections.
  • the panels were switched to their white optical state, and a digital image of each section was taken. All pixels of the digital image were analyzed to determine whether they were above or below a threshold (and thus white or dark) and the total area of white and dark pixels was calculated, and hence the percentage void area, the black pixels being assumed to represent void area.
  • the thickness of the lamination adhesive layer initially formed on the release sheet was adjusted to provide nominal adhesive thicknesses of 12, 14, 16 and 16 ⁇ m inn the final displays.
  • the actual thicknesses measured are as shown in Table 1 below: TABLE 1 Target Measured Standard Thickness ( ⁇ m) thickness ( ⁇ m) Deviation ( ⁇ m) 12 11.7 0.8 14 13.6 0.9 16 15.6 1.3 18 18.1 1.5
  • an electro-optic display is constructed with a front substrate comprising a polymeric film (through which an observer views the display) and a glass or similar rigid backplane, differences in coefficient of thermal expansion (CTE) and coefficient of relative humidity expansion (CHE) between the materials used in the construction create stresses and strains large enough to cause curling or warping of the display.
  • CTE coefficient of thermal expansion
  • CHE coefficient of relative humidity expansion
  • the CTE of the polymeric film will typically be substantially greater than that of the rigid backplane.
  • the front substrate lies parallel to the backplane, as illustrated in FIG. 1A of the accompanying drawings (the electro-optic medium is omitted from FIGS. 1A and 1B for ease of illustration)
  • the polymeric film substrate enters into a state of compression because its bond to the rigid glass substrate prevents the polymeric from expanding as much as it desires. Under the action of this compressive stress, the polymeric film buckles.
  • the critical buckling force P crit per unit width may be predicted to a first order using the following relationship (the one-dimensional case is considered for simplicity): P crit ⁇ ( kEt 3 3 ) 1 / 2 where k is the tensile stiffness of the adhesive connecting the electro-optic material layer to the backplane, E is the Young's modulus of the polymeric front substrate, and t is the thickness of this front substrate. From this simple relationship, it can be seen that it is desirable to increase the tensile stiffness of the adhesive, the stiffness of the bond between the adhesive and the backplane and the stiffness of the bond between the adhesive and the electro-optic layer.
  • adhesion promoters such as 1-propanamine, 3-(trimethoxysilyl) (more systematically named 3-amino-propyltrimethoxysilane), 3-aminopropyldimethylethoxysilane, hexamethyldisilizane or other such materials.
  • the front plane laminate described in the aforementioned 2004/0027327 is preferably prepared (when an encapsulated electrophoretic medium is used) by first coating and drying a film of capsules and polymeric binder on a transparent conductor (for example, indium tin oxide or conductive polymer) carried on the polymeric film substrate (for which poly(ethylene terephthalate) or PEN are preferred).
  • a transparent conductor for example, indium tin oxide or conductive polymer
  • the capsules themselves vary in size, but are preferably 30 ⁇ m to 50 ⁇ m (85% confidence), more preferably 30 ⁇ m to 50 ⁇ m (99% confidence), and even more preferably 35 ⁇ m to 45 ⁇ m (99% confidence).
  • FIG. 2 illustrates schematically a front plane laminate comprising a transparent front substrate 100 through which the observer views the display.
  • This front substrate 100 carries a light-transmissive conductive layer 102 , on which is formed an electrophoretic layer 104 , illustrated as comprising a plurality of capsules dispersed in a binder.
  • an electrophoretic layer 104 illustrated as comprising a plurality of capsules dispersed in a binder.
  • a release sheet 106 On the opposed side of the electrophoretic layer 104 from the conductive layer 102 .
  • a layer of lamination adhesive is normally provided between the electrophoretic layer 104 and the release sheet 106 , but this lamination adhesive is omitted from FIGS. 2 and 3 for ease of illustration.
  • FIG. 3 of the accompanying drawings is a schematic illustration similar to FIG. 2 but showing the front plane laminate with the release sheet 106 removed, and showing the peak-to-valley roughness and local surface angle (as discussed below) of the electrophoretic layer 104
  • the front substrate is thick enough to enhance the mechanical ruggedness of the display, for example by conferring impact resistance.
  • the front substrate is thinner than 20 mil (approx. 0.5 mm). Even more preferably the front substrate is thinner than 10 mil (approx. 0.25 mm).
  • the release sheet which is preferably also formed from poly(ethylene terephthalate) or PEN, and which may, for reasons explained in the aforementioned 2004/0027327 bear a conductive layer on its surface facing the electro-optic medium. If the release sheet is too thin, it will follow the contours of the electro-optic layer. If these contours are too closely followed, one finds that, after lamination of the front plane laminate to the backplane, many air voids exist between the backplane and the layer of lamination adhesive. However, if the release sheet is too thick, the release sheet becomes more costly and it becomes very difficult to maintain the integrity of the front plane laminate if it is rolled up during storage.
  • the release sheet be thinner than 15 mil (approx. 0.37 mm), desirably thinner than 10 mil (approx. 0.25 mm).
  • FIG. 2 Since the release sheet is thinner than the front substrate, the topography of the uneven capsule film is mainly transferred to the release sheet 106 , as shown in FIG. 2 .
  • the uneven topography (known in the imaging industry as “orange peel”) is most apparent on the exposed surface of the release sheet, but is evident to some degree on the exposed surface of the front substrate.
  • FIGS. 2 and 3 show the various layers of the display inverted with respect to FIG. 1 , so that in FIGS. 2 and 3 the exposed surface of the front substrate, which forms the viewing surface of the display, is at the bottom of the Figure.)
  • the adhesive and/or binder material properties and thickness and to apply the adhesive and/or binder in such a way that all interstitial spaces between capsules and all areas above capsules are coated with adhesive and/or binder.
  • the thinnest region of the adhesive and/or binder should be less than 30 ⁇ m, more preferably less than 20 ⁇ m, and desirably less than 10 ⁇ m.
  • FIG. 3 which is a schematic side elevation similar to that of FIG. 2 but after removal of the release sheet from the FPL, this flatness requirement places limits on the surface roughness (measured as peak-to-valley roughness, ⁇ h in FIG. 3 ) of the front plane laminate after removal of the release sheet.
  • peak-to-valley roughness be less than 15 ⁇ m, preferably less than 10 ⁇ m, and most desirably less than 5 ⁇ m.
  • the local surface angles (indicated as ⁇ in FIG. 3 ) on the front plane laminate be less than 15° from the horizontal, preferably less than 10° from the horizontal, and most desirably less than 5° from the horizontal. This restriction on surface angles helps to ensure that lamination process speeds can be high enough for mass production.
  • FIGS. 4A and 4B of the accompanying drawings show respectively a photomicrograph of a front plane laminate with long wavelength peak-to-valley roughness greater than 5 ⁇ m, and the voids that result after thermal lamination of this relatively rough front plane laminate to a glass backplane. These voids would be likely to produce unacceptable artifacts in a commercial electro-optic display.
  • the optimum adhesive thickness for adhesive filling of interstitial sites and covering the largest capsules may vary with capsule size distribution. As an example, assume the capsule size distribution ranges from 20 ⁇ m to 60 ⁇ m (i.e., assume 99% of capsules fall within this size range). After drying the capsules on the front substrate, their thickness typically drops by about 50% due to coating and drying dynamics, so the largest dried capsules will be some 30 ⁇ m in thickness and the smallest capsules will be some 10 ⁇ m in thickness.
  • the peak-to-valley roughness of the resulting capsule layer will be slightly larger than 20 ⁇ m (30 ⁇ m for the largest capsule minus 10 ⁇ m for the smallest capsule, plus the distance from the top of the smallest capsule to the bottom of an interstitial site next to a small capsule).
  • Example 2 is now given to show how the peak-to-valley roughness of a front plane laminate affects the formation of voids after lamination of the front plane laminate to an experimental backplane.
  • Front plane laminates and experimental displays were prepared in substantially the same manner as in Example 1, except that either no lamination adhesive was applied to the capsule binder layer or (nominally) 12, 18, 25, 35 or 45 ⁇ m layers of a custom polyurethane-based lamination adhesive was applied.
  • the root mean square surface roughness and the peak-to-valley roughness of the exposed surfaces of the front plane laminate, after removal of the release sheet, were measured using a KLA-Tencor Surface Profiler with a 2000 ⁇ m (2 mm) scan length.
  • the laminates were then laminated to the backplane and the formation of voids immediately after lamination was observed; these voids are referred to as “t0 voids” in Table 3 below.
  • the experimental displays thus formed were stored at 90° C.
  • the buckling instability of layers in hybrid displays is a complex phenomena that could jeopardize the success of such products in the marketplace, especially as specifications on electronic displays become more and more demanding as competitive technologies such as liquid crystal displays become more refined.
  • the present invention provides pathways for mitigating this problem which are well suited to large scale manufacture.

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WO2005010598A3 (fr) 2005-05-12
US7957053B2 (en) 2011-06-07
US7636191B2 (en) 2009-12-22
US20060176267A1 (en) 2006-08-10
US20100039697A1 (en) 2010-02-18
WO2005010598A2 (fr) 2005-02-03

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