Substrate free flexible liquid crystal displays

• US 20060066803A1
• Filed: 09/30/2004
• Published: 03/30/2006
• Est. Priority Date: 09/30/2004
• Status: Abandoned Application

• Current Assignee: Industrial Technology Research Institute
• Original Assignee: Industrial Technology Research Institute
• Inventors: Aylward, Peter T., Montbach, Erica N.
• Application Number:
  US10/954,722
• Publication Number:
  US 20060066803A1
• Time in Patent Office: Days
• US Class Current: 349/158
• CPC Class Codes: G02F 1/133305 Flexible substrates, e.g. plastics, organic film
• CPC Class Codes: G02F 1/13473 for wavelength filtering or for colour display without the use of colour mosaic filters
• CPC Class Codes: G02F 1/13478 based on selective reflection
• CPC Class Codes: G02F 1/13613 the semiconductor element being formed on a first substrate and thereafter transferred to the final cell substrate
• CPC Class Codes: G02F 2202/22 Antistatic materials or arrangements

Abstract

The present invention relates to a flexible multi-color display comprising an optional substrate, at least one independently switchable electrically modulated imaging layer between an upper conductive layer and a lower conductive layer, wherein the number of said optional substrate is less than or equal to the number of said at least one independently switchable electrically modulated imaging layer. The present invention also relates to a display comprising portions of a flexible multi-color displays produced separately and laminated to gether to form a final display, as well as displays having removable carrier/transport substrates and methods for making the same.

Claims

1. A flexible multi-color display comprising an optional substrate, at least one independently switchable electrically modulated imaging layer between an upper conductive layer and a lower conductive layer, wherein the number of said optional substrate is less than or equal to the number of said at least one independently switchable electrically modulated imaging layer.

2. The display of claim 1 wherein said substrate is transparent.

3. The display of claim 2 wherein said transparent substrate comprises polyester.

4. The display of claim 2 wherein said transparent substrate comprises polycarbonate.

5. The display of claim 2 wherein said transparent substrate comprises polyethylene naphthalate (PEN).

6. The display of claim 2 wherein said transparent substrate comprises acetate.

7. The display of claim 2 wherein said transparent substrate comprises polyethersulfone.

8. The display of claim 2 wherein said transparent substrate comprises at least one member selected from the group consisting of polyolefin, polyester, polycarbonate, acetate, cyclic polyolefin, polyethersulfone, and polyamide.

9. The display of claim 1 wherein said substrate is removable.

10. The display of claim 9 wherein said removable substrate further comprises at least one adhesion modifying layer.

11. The display of claim 10 wherein said adhesion modifying layer is a release layer.

12. The display of claim 10 wherein said adhesion modifying layer has an adhesive strength of less than 250 N/m.

13. The display of claim 12 wherein the adhesion between the first-pass film and the transport substrate is greater than 0.3 N/m.

14. The display of claim 10 wherein said removable substrate comprises at least one member selected from the group consisting of polyester, polycarbonate, polyolefin, acetate, and paper.

15. The display of claim 11 wherein said release layer comprises an acetate film.

16. The display of claim 15 wherein said acetate film comprises cellulose ester.

17. The display of claim 11 wherein said release layer comprises a polyvinyl butyral film.

18. The display of claim 17 wherein the adhesion between the polyvinyl butyral film and the transport substrate is less than 250 N/m.

19. The display of claim 11 wherein said release layer comprises polycarbonate film.

20. The display of claim 19 wherein the adhesion between said polycarbonate film and the transport substrate is from 0.5 to 25 N/m.

21. The display of claim 11 wherein said at least one adhesion modifying layer comprises an adhesive layer.

22. The display of claim 21 wherein said adhesive layer is optically clear.

23. The display of claim 1 wherein said electrically modulated imaging layer comprises a light modulating material.

24. The display of claim 23 wherein said light modulating material comprises a liquid crystal material.

25. The display of claim 24 wherein said liquid crystal material is a chiral nematic liquid crystal material.

26. The display of claim 24 wherein said liquid crystal material is a polymer dispersed cholesteric liquid crystal layer.

27. The display of claim 26 wherein said polymer is gelatin.

28. The display of claim 26 wherein said polymer is polyvinyl alcohol.

29. The display of claim 26 wherein said polymer is latex.

30. The display of claim 26 wherein said polymer is water soluble.

31. The display of claim 26 wherein said polymer dispersed cholesteric liquid crystal layer further comprises a hardener.

32. The display of claim 1 wherein said electrically modulated imaging layer comprises electrochromic materials.

33. The display of claim 1 wherein said electrically modulated imaging layer comprises more than one imaging layer and wherein each of said electrically modulated imaging layers has a refractive index and said refractive index of each of said electrically modulated imaging layers is matched to the refractive index of said upper conductive layer and the refractive index of said lower conductive layer.

34. The display of claim 33 wherein the difference between said refractive index of said electrically modulated imaging layer and said refractive index of said upper conductive layer and said refractive index of said lower conductive layer is from 0.15 to 0.01.

35. The display of claim 1 wherein said at least one independently switchable electrically modulated imaging layer between an upper conductive layer and a lower conductive layer comprises a blue independently switchable liquid crystal layer, a green independently switchable liquid crystal layer and a red independently switchable liquid crystal layer.

36. The display of claim 1 wherein said at least one of said upper conductive layer and said lower conductive layer is patterned to form a regular grid pattern.

37. The display of claim 1 wherein at least one of said upper conductive layer and said lower conductive layer comprises ITO.

38. The display of claim 1 wherein said at least one of said upper conductive layer and said lower conductive layer comprises polythiphene

39. The display of claim 38 wherein said polythiophene is combined with a crosslinked silane

40. The display of claim 1 wherein at least one of said upper conductive layer and said lower conductive layer comprise a transparent conductive material.

41. The display of claim 40 wherein said transparent conductive material comprises a material transparent to visible light in the range from 400 to 700 nm.

42. The display of claim 40 wherein said transparent conductive material has a percent transmission of between 80 and 95% across the visible spectrum.

43. The display of claim 1 wherein said upper conductive layer is a black-colored conductive layer.

44. The display of claim 43 wherein said black-colored conductive layer comprises a black UV curable carbon conductor.

45. The display of claim 43 wherein said black-colored conductive layer

is a color contrasting layer containing gelatin and cyan, magenta, yellow, and black pigments to form a black layer.

46. The display of claim 1 further comprising an environmental protection layer.

47. The display of claim 1 further comprising a dielectric insulating layer.

48. The display of claim 1 wherein said display further comprises a radiation absorbing layer.

49. The display of claim 48 wherein said radiation absorbing layer is a color contrast layer.

50. The display of claim 49 wherein said color contrast layer comprises gelatin and cyan, magenta, yellow, and black pigments to form a black layer.

51. The display of claim 1 wherein said display further comprises an antistatic layer.

52. The display of claim 1 wherein said display further comprises at least one antireflection coating.

53. The display of claim 52 wherein said antireflection coating comprises at least one thin dielectric or metallic film.

54. The display of claim 52 wherein said antireflection coating comprises magnesium fluoride.

55. The display of claim 52 wherein said antireflection coating has a Fresnel value of less than 0.5% over the visible range.

56. The display of claim 52 wherein said antireflection coating has a surface reflection from 400-800 nm of less than 1%.

57. The display of claim 1 further comprising a layer having an antiglare treated surface closest to the viewer.

58. The display of claim 57 wherein said antiglare treated surface is a roughened surface.

59. The display of claim 58 wherein said roughened layer comprises nano-particles of SiO₂.

60. The display of claim 57 wherein said layer having an antiglare treated surface comprises a glass or plastic overlay etched with a solvent.

61. The display of claim 57 wherein said layer having an antiglare treated surface comprises glass etched with buffered hydrofluoric acid.

62. The display of claim 57 wherein said layer having an antiglare treated surface comprises plastic etched with organic solvent.

63. A display comprising a top part having an upper and lower layer and a bottom part having an upper and lower layer, wherein said lower layer of said top part and said upper layer of said bottom part are laminated together, wherein said top part comprises an upper substrate layer and a lower conductive layer and wherein said bottom part comprises an upper liquid crystal layer, a lower transparent substrate layer, and a conductive layer between said upper liquid crystal layer and said lower transparent substrate layer.

64. The display of claim 63 wherein said upper substrate is a black polyester substrate.

65. The display of claim 63 wherein said upper substrate is a transport sheet as coated with a release layer of acetate.

66. The display of claim 63 wherein said substrate is transparent.

67. The display of claim 66 wherein said transparent substrate comprises at least one member selected from the group consisting of polyolefin, polyester, polycarbonate, acetate, cyclic polyolefin, polyethersulfone, and polyamide.

68. The display of claim 63 wherein said substrate is removable.

69. The display of claim 68 wherein said removable substrate further comprises at least one adhesion modifying layer.

70. The display of claim 69 wherein said adhesion modifying layer is a release layer.

71. The display of claim 69 wherein said adhesion modifying layer has an adhesive strength of less than 250 N/m.

72. The display of claim 71 wherein the adhesion between the first-pass film and the transport substrate is greater than 0.3 N/m.

73. The display of claim 69 wherein said removable substrate comprises at least one member selected from the group consisting of polyester, polycarbonate, polyolefin, acetate, and paper.

74. The display of claim 70 wherein said release layer comprises an acetate film.

75. The display of claim 70 wherein said release layer comprises a polyvinyl butyral film.

76. The display of claim 70 wherein said release layer comprises polycarbonate film.

77. The display of claim 70 wherein said at least one adhesion modifying layer comprises an adhesive layer.

78. The display of claim 63 wherein said electrically modulated imaging layer comprises a light modulating material.

79. The display of claim 78 wherein said light modulating material comprises a liquid crystal material.

80. The display of claim 79 wherein said liquid crystal material is a chiral nematic liquid crystal material.

81. The display of claim 79 wherein said liquid crystal material is a polymer dispersed cholesteric liquid crystal layer.

82. The display of claim 81 wherein said polymer dispersed cholesteric liquid crystal layer further comprises a hardener.

83. The display of claim 63 wherein said electrically modulated imaging layer comprises electrochromic materials.

84. The display of claim 63 wherein said electrically modulated imaging layer comprises more than one imaging layer and wherein each of said electrically modulated imaging layers has a refractive index and said refractive index of each of said electrically modulated imaging layers is matched to the refractive index of said upper conductive layer and the refractive index of said lower conductive layer.

85. The display of claim 84 wherein the difference between said refractive index of said electrically modulated imaging layer and said refractive index of said upper conductive layer and said refractive index of said lower conductive layer is from 0.15 to 0.01.

86. The display of claim 63 wherein said at least one independently switchable electrically modulated imaging layer between an upper conductive layer and a lower conductive layer comprises a blue independently switchable liquid crystal layer, a green independently switchable liquid crystal layer and a red independently switchable liquid crystal layer.

87. The display of claim 63 wherein said at least one of said upper conductive layer and said lower conductive layer is patterned to form a regular grid pattern.

88. The display of claim 63 wherein at least one of said upper conductive layer and said lower conductive layer comprise a transparent conductive material.

89. The display of claim 63 wherein said upper conductive layer is a black-colored conductive layer.

90. The display of claim 63 further comprising a functional layer.

91. The display of claim 90 wherein said laminated layers are laminated by means of an adhering material positioned therebetween.

92. The display of claim 91 wherein said adhering material is optically clear.

93. The display of claim 63 wherein said bottom part comprises an upper first conductive layer, a lower substrate layer of said bottom part, a liquid crystal layer of said bottom part therebetween, and a second conductive layer between said lower substrate layer of said bottom part and said liquid crystal layer of said bottom part, wherein said top part comprises an upper third conductive layer of said top part, a lower substrate layer of said top part, a liquid crystal layer of said top part therebetween, and a fourth conductive layer between said lower substrate layer of said top part and said liquid crystal layer of said top part, and further comprising a middle part having an upper fifth conductive layer of said middle part, a lower substrate layer of said middle part, a liquid crystal layer of said middle part therebetween, and a sixth conductive layer between said lower substrate layer of said middle part and said liquid crystal layer of said middle part, and wherein said lower layer of said top part is laminated to said upper layer of said middle part and said lower layer of said middle part is laminated to said upper layer of said bottom part.

94. The display of claim 93 wherein said liquid crystal layer of said top part is red, said liquid crystal layer of said middle part is green, and said liquid crystal layer of said bottom part is blue.

95. The display of claim 93 wherein said conductive layers are patterned conductive layers.

96. The display of claim 93 wherein at least one of said conductive layers comprises polythiophene.

97. The display of claim 93 wherein at least one of said conductive layers comprises ITO.

98. The display of claim 93 wherein said laminated layers are laminated by means of an adhering material positioned therebetween.

99. The display of claim 98 wherein said adhering material is optically clear.

100. The display of claim 93 wherein said upper substrate layer of said top part further comprises a black-colored absorbing layer opposite said first conductive layer.

101. The display of claim 100 wherein said black-colored absorbing layer is a color contrasting layer containing gelatin and cyan, magenta, yellow, and black pigments to form a black layer.

102. The display of claim 93 wherein said third conductive layer is an etched or printed black conductive layer.

103. The display of claim 102 wherein said etched or printed black conductive layer is a black UV curable carbon conductor

104. The display of claim 63 wherein said bottom part comprises a lower substrate layer of said bottom part, an upper first conductive layer of said bottom part, a liquid crystal layer of said bottom part therebetween, and a second conductive layer between said lower substrate layer of said bottom part and said liquid crystal layer of said bottom part, wherein said top part comprises an upper black-colored absorbing layer of said top part, a lower substrate layer of said top part, a liquid crystal layer of said top part therebetween, a third conductive layer between said upper black-colored absorbing layer of said top part and said liquid crystal layer of said top part and a fourth conductive layer between said lower substrate layer of said top part and said liquid crystal layer of said top part, and further comprising a middle part having an upper fifth conductive layer of said middle part, a lower substrate layer of said middle part, a liquid crystal layer of said middle part therebetween, and a sixth conductive layer between said lower substrate layer of said middle part and said liquid crystal layer of said middle part, and wherein said lower layer of said top part is laminated by means of an adhesive layer to said upper layer of said middle part and said lower layer of said middle part is laminated by means of an adhesive layer to said upper layer of said bottom part.

105. The display of claim 104 wherein said upper black-colored absorbing layer of said top part further comprises a black-colored substrate layer opposite said third conductive layer.

106. The display of claim 63 wherein bottom part comprises an upper transparent substrate of said bottom part, a lower etched first conductive layer of said bottom part, a liquid crystal layer of said bottom part therebetween, and a second conductive layer of said bottom part between said upper substrate of said bottom part, and said liquid crystal layer of said bottom part, wherein said top part comprises an upper black third conductive layer of said top part, a lower fourth conductive layer of said top part, a liquid crystal layer of said top part therebetween, and further comprising a middle part having an upper substrate layer of said middle part, a lower fifth conductive layer of said middle part, a liquid crystal layer of said middle part therebetween, and a sixth conductive layer between said upper substrate layer of said middle part and said liquid crystal layer of said middle part, and wherein said lower layer of said top part is laminated by means of an adhesive layer to said upper layer of said middle part and said lower layer of said middle part is laminated by means of an adhesive layer to said upper layer of said bottom part.

107. The display of claim 106 wherein said upper black third conductive layer of said top part further comprises a black-colored substrate layer opposite said liquid crystal layer of said top part.

108. The display of claim 63 wherein said top part comprises an upper black first conductive layer of said top part, a lower second conductive layer of said top part, and a liquid crystal layer of said top part therebetween and a bottom part comprising an upper third conductive layer of said bottom part, a lower fourth conductive layer of said bottom part, a substrate layer of said bottom part between said upper third conductive layer of said bottom part and said lower fourth conductive layer of said bottom part, wherein said substrate layer of said bottom part has a side bearing a fifth conductive layer and a side bearing a sixth conductive layer, a liquid crystal layer of said bottom part between said lower fourth conductive layer of said bottom part and said sixth conductive layer and a liquid crystal layer of said bottom part between said upper third conductive layer of said bottom part and said fifth conductive layer, wherein said lower layer of said top part and said upper layer of said bottom part are laminated by means of an adhesive layer.

109. The display of claim 63 wherein said bottom part comprises an upper first conductive layer, a lower substrate layer of said bottom part, a liquid crystal layer of said bottom part therebetween, and a second conductive layer between said lower substrate layer of said bottom part and said liquid crystal layer of said bottom part, wherein said top part comprises an upper third conductive layer of said top part, a lower dielectric insulating layer of said top part, a liquid crystal layer of said top part therebetween, and a fourth conductive layer between said lower substrate layer of said top part and said liquid crystal layer of said top part, and further comprising a middle part having an upper fifth conductive layer of said middle part, a lower dielectric insulating layer of said middle part, a liquid crystal layer of said middle part therebetween, and a sixth conductive layer between said lower substrate layer of said middle part and said liquid crystal layer of said middle part, and wherein said lower layer of said top part is laminated to said upper layer of said middle part and said lower layer of said middle part is laminated to said upper layer of said bottom part.

110. The display of claim 109 wherein said dielectric insulating layer comprises polyurethane.

111. The display of claim 109 wherein said lower substrate layer of said bottom part comprises a transport sheet.

112. The display of claim 111 wherein said transport sheet comprises a sheet bearing a layer of clear polymer, wherein said layer of clear polymer has poor adhesion to said sheet, and wherein said layer of clear polymer serves as the separation interface between said sheet and said liquid crystal layer of said bottom part.

113. A coated display comprising at least one coated liquid crystal assembled display cell, wherein said liquid crystal assembled display cell comprises a coated transparent conductive layer, a black etched conductor coated onto a substrate that is not in the active view plane of the display, and a liquid crystal layer coated between said transparent conductive layer and said black etched conductor.

114. A coated display comprising a substrate that is not in the active view plane of the display, a black conductive layer coated thereon, a third liquid crystal layer coated on the side of said black conductive layer opposite said substrate, a fifth conductive layer coated on the side of said third liquid crystal layer opposite said black conductive layer, a second dielectric insulating layer coated on the side of said fifth conductive layer opposite said third liquid crystal layer, a fourth conductive layer coated on the side of said second dielectric insulating layer opposite said fifth conductive layer, a second liquid crystal layer coated on the side of said fourth conductive layer opposite said second dielectric insulating layer, a third conductive layer coated on the side of said second liquid crystal layer opposite said fourth conductive layer, a first dielectric insulating layer coated on the side of said third conductive layer opposite said second liquid crystal layer, a second conductive layer coated on the side of said first dielectric insulating layer opposite said third conductive layer, a first liquid crystal layer coated on the side of said second conductive layer opposite said first dielectric insulating layer, and a first conductive layer coated on the side of said first liquid crystal layer opposite said second conductive layer.

115. A method of forming a flexible multi-color display comprising providing a removable substrate;

and applying at least one independently switchable light modulating layer between an upper conductive layer and a lower conductive layer, wherein the number of said at least one substrate is less than or equal to the number of said at least one modulating layer.

116. The method of claim 115 wherein said applying comprises coating.

117. The method of claim 115 wherein said removable film comprises polyvinyl butyral.

118. The method of claim 115 wherein said providing a removable film comprises coating polyvinyl butyral (PVB) resin dissolved in at least one organic solvent.

119. The method of claim 118 wherein said organic solvent further comprises plasticizer or surfactant.

120. The method of claim 115 wherein said removable film comprises polycarbonate film.

121. The method of claim 115 wherein said providing a removable film comprises coating a polycarbonate resin dissolved in an organic solvent.

122. The method of claim 121 wherein said organic solvent further comprises plasticizer or surfactant.

123. The method of claim 115 wherein said removable film comprises an acetate film.

124. The method of claim 115 wherein said providing a removable film comprises coating a cellulose ester dissolved in at least one organic solvent.

125. The method of claim 124 wherein said organic solvent further comprises plasticizer or surfactant.

126. The method of claim 115 further comprising removing said removable substrate.

127. A method of forming a flexible multi-color display comprising providing a substrate and applying an upper patterned conductive layer thereto to form an upper display portion;

providing a transparent substrate and applying a lower patterned conductive layer followed by an electrically modulate imaging layer thereto to form a lower display portion; and

laminating said upper display portion to said lower display portion.