Display with self-illuminatable image and method for making the display substrate and for making the image

• US 20060174993A1
• Filed: 02/03/2006
• Published: 08/10/2006
• Est. Priority Date: 02/04/2005
• Status: Abandoned Application

• Current Assignee: Appleton Coated LLC (Sequana Capital)
• Original Assignee: Appleton Coated LLC (Sequana Capital)
• Inventors: Bery, Yuri A., Osterberg, Douglas L.
• Application Number:
  US11/346,180
• Publication Number:
  US 20060174993A1
• Time in Patent Office: Days
• US Class Current: 156/67
• CPC Class Codes: C09D 11/52 Electrically conductive inks

Abstract

A substrate has a self-illuminatable image. The substrate, which can be paper, will first receive conductive ink. The substrate can be calendered to provide a smooth, sealed surface for the ink. On top of the conductive ink, one or more dielectric layers can be provided followed by a phosphor-containing layer. A smoothing layer can then be provided. A second layer of conductive ink is provided on the smoothing layer. The conductive layers can be applied in any desired pattern. The first underlying conductive ink layer and the second overlying conductive ink layer will match the image in certain portions. When a current is passed through the conductive inks, phosphor in the phosphor-containing layer will be excited in order to illuminate the image. After printing of the first conductive layer, the substrate can be calendered to help connect conductive particles in the ink. A one-sided or two-sided display can be provided.

Claims

1. A method for making a display having a self-illuminatable image thereon, the method comprising the steps of:

providing a substrate;

calendering the substrate;

applying an image to be illuminated on the substrate after the step of calendering; and

providing an electrical connection to supply power to the image when the image is to be illuminated.

2. The method of claim 1, further comprising the step of coating the substrate before the step of calendering to thereby seal and smooth the substrate.

3. The method of claim 2, wherein the step of coating the substrate comprises applying at least one of calcium carbonate and kaolin to the substrate.

4. The method of claim 1, further comprising the step of increasing resolution of the image by coating the substrate before the step of applying the image.

5. The method of claim 2, wherein the step of coating further comprises the step of at least one of varnishing the substrate, coating the substrate with aqueous coating and coating the substrate with ultraviolet curable coating before the step of calendering to thereby seal and smooth the substrate.

6. The method of claim 1, wherein the step of applying an image comprises the step of printing the image on the substrate.

7. The method of claim 6, wherein the step of printing includes the steps of printing a first layer on the substrate and then printing a second layer on the substrate, at least a portion of the first layer being directly below a portion of the second layer such that the first and second layers overlap at portions of the image to be illuminated, the first and second layers being a part of the electrical connection.

8. The method of claim 7, wherein the first and second layers are printed with conductive ink and wherein the method further comprises the steps of:

providing a controller for controlling illumination of the image; and

connecting the first layer to the controller; and

connecting the second layer to the controller.

9. The method of claim 8, further comprising the steps of providing a power source on the substrate to drive the controller and illuminate the display.

10. The method of claim 7, wherein the first layer is printed as a series of parallel lines and the second layer is printed as a series of parallel lines perpendicular to the lines of the first layer whereby the image to be illuminated includes a plurality of pixels.

11. The method of claim 7, wherein the first layer and second layer are overlapping images.

12. The method of claim 7, further comprising the step of using paper as the substrate.

13. The method of claim 7, wherein at least the second layer is printed with conductive ink and wherein the method further comprising the step of reducing an amount of conductive ink used in the second layer by providing a smoothing layer beneath the second layer, the smoothing layer providing a relatively flat surface to print the second layer of conductive ink.

14. The method of claim 13, wherein a shape of the smoothing layer matches a shape of the second layer.

15. The method of claim 14, wherein the smoothing layer is a conductive layer.

16. The method of claim 13, further comprising the steps of:

providing at least one dielectric layer on a side of the first layer opposite to the substrate;

placing a phosphor-containing layer on the at least one dielectric layer;

providing the smoothing layer on a side of the phosphor-containing layer opposite the dielectric layer; and

printing the second layer on a side of the smoothing layer opposite the phosphor-containing layer.

17. The method of claim 16, wherein a plurality of dielectric layers are provided.

18. The method of claim 1, further comprising the step of using paper as the substrate.

19. The method of claim 1, wherein the step of applying the image further comprises the steps of:

printing a first layer on the substrate;

providing at least one dielectric layer over the first layer;

providing a phosphor-containing layer on a top of the at least one dielectric layer; and

printing a second layer above the at least one dielectric layer, the first and second layers being a part of the electrical connection.

20. The method of claim 19, further comprising the step of providing a smoothing layer between the second layer and the phosphor-containing layer.

21. The method of claim 19, further comprising the step of providing a diffusion layer on the second layer to increase uniformity of emitted light.

22. The method of claim 19, wherein the first and second layers are printed with conductive ink and wherein overlapping portions of the first and second layers form the image to be illuminated.

23. The method of claim 1, wherein the step of applying the image further comprises the steps of:

printing a first layer on a first side of the substrate;

providing a phosphor-containing layer on an opposite side of the substrate; and

printing a second layer on the side of the substrate with the phosphor-containing layer,

whereby the substrate is a dielectric layer.

24. The method of claim 23, further comprising the step of using paper as the substrate, the paper containing at least one of titanium dioxide and barium titanate to increase dielectric constant.

25. The method of claim 23, further comprising the step of providing a smoothing layer between the second layer and the phosphor-containing layer.

26. The method of claim 23, further comprising the step of providing a diffusion layer on the second layer to increase uniformity of emitted light.

27. The method of claim 23, wherein the first and second layers are printed with conductive ink and wherein overlapping portions of the first and second layers form the image to be illuminated.

28. The method of claim 1, wherein the step of applying the image further comprises the steps of:

providing a phosphor-containing layer on each side of the substrate, the substrate having a first side and a second side;

printing a first layer on a first one of the phosphor-containing layers on the first side of the substrate; and

printing a second layer on a second one of the phosphor-containing layers on the second side of the substrate,

whereby the substrate is a dielectric layer.

29. The method of claim 28, further comprising the step of using paper as the substrate, the paper containing at least one of titanium dioxide and barium titanate to increase dielectric constant.

30. The method of claim 29, further comprising the step of coating the paper to increase electrical breakdown resistance.

31. The method of claim 30, comprising the step of using at least one of calcium carbonate and kaolin in the coating.

32. The method of claim 28, further comprising the step of providing a smoothing layer between the first layer and the first phosphor-containing layer and providing another smoothing layer between the second layer and the second phosphor-containing layer.

33. The method of claim 28, further comprising the step of providing a diffusion layer on the first layer and providing a diffusion layer on the second layer, the diffusion layers increasing uniformity of emitted light.

34. The method of claim 28, wherein the first and second layers are printed with conductive ink and wherein overlapping portions of the first and second layers form the image to be illuminated.

35. The method of claim 1, wherein the step of applying the image further comprises the steps of:

printing a first layer of conductive ink on the substrate, the first layer being a part of the electrical connection; and

calendering the substrate and the first layer after the step of printing to thereby crush the conductive ink to connect conductive particles in the ink to ensure a continuous electrical connection through the first layer.

36. The method of claim 35, further comprising the step of applying heat to the substrate during the step of calendering to decrease the viscosity of the conductive ink.

37. The method of claim 36, wherein the temperature is in the range of 100-200°

C.

38. The method of claim 36, wherein the pressure is in the range of 200-1000 psi.

39. The method of claim 35, further comprising the step of printing a second layer of conductive ink on the substrate, at least a portion of the first layer being directly below a portion of the second layer such that the first and second layer overlap at portions of the image to be illuminated.

105. The method of claim 7, further comprising the steps of providing two substrates which have been treated by the recited steps and laminating back sides of the substrates together to form a two-sided display.

106. The method of claim 7, wherein the step of applying an image comprises applying images to both sides of the substrate, the steps of printing the fist layer and printing the second layer being done to both sides of the substrate.

40. A method for making a display having a self-illuminatable image, the method comprising the steps of:

providing a substrate;

placing a first layer of conductive ink on the substrate, the conductive ink having a plurality of conductive particles; and

applying pressure to the substrate and conductive ink to connect the conductive particles in the ink to ensure a continuous electrical connection through the first layer and therefore increase electrical conductivity of the first layer.

41. The method of claim 40, further comprising the step of applying temperature to the substrate during the step of applying pressure to decrease viscosity of the conductive ink.

42. The method of claim 41, wherein the temperature is in the range of 100-200°

C.

43. The method of claim 41, wherein the pressure is in the range of 200-1000 psi.

44. The method of claim 40, further comprising the step inducing contact of conductive particles in the conductive ink by cooling the substrate and conductive ink after the step of applying pressure.

45. The method of claim 40, further comprising the step of calendering the paper before the step of placing a first layer of conductive ink.

46. The method of claim 45, further comprising the step coating the substrate before the step of calendering to thereby seal and smooth the substrate.

47. The method of claim 46, wherein the step of coating the substrate comprises applying at least one of calcium carbonate and kaolin to the substrate.

48. The method of claim 40, further comprising the step of increasing resolution of the image by coating the substrate before the step of applying the image.

49. The method of claim 48, wherein the step of coating further comprises the step of at least one of varnishing the substrate, coating the substrate with aqueous coating and coating the substrate with ultraviolet curable coating before the step of placing the first layer of ink to thereby seal and smooth the substrate.

50. The method of claim 40, wherein the step of applying pressure comprises calendering the substrate with the first layer of conductive ink.

51. The method of claim 40, further comprising the step of using paper as the substrate.

52. The method of claim 40, further comprising the step of placing a second layer of conductive ink on the substrate, at least a portion of the first layer being directly below a portion of the second layer such that the first and second layers overlap at portions of the image to be illuminated.

53. The method of claim 52, wherein the step of placing the first layer comprises printing the first layer on the substrate, the first layer being printed as a series of parallel lines and the second layer being printed as a series of parallel lines perpendicular to the lines of the first layer whereby the image to be illuminated includes a plurality of pixels.

54. The method of claim 52, wherein the step of placing the first layer comprises printing the first layer on the substrate, the first layer and the second layer being overlapping images.

55. The method of claim 52, further comprising the step of providing a smoothing layer beneath the second layer to provide a flat surface for the second layer of conductive ink.

56. The method of claim 55, wherein a shape of the smoothing layer matches a shape of the second layer, the smoothing layer being a conductive layer.

57. The method of claim 55, further comprising the steps of:

providing at least one dielectric layer on a side of the first layer opposite to the substrate;

placing a phosphor-containing layer on the at least one dielectric layer; and

printing a second layer of conductive ink on the smoothing layer,

at least a portion of the first layer and the second layer overlap at portions of the image to be illuminated.

58. The method of claim 57, further comprising the step of providing a smoothing layer between the phosphor-containing layer and the second layer of conductive ink.

59. The method of claim 57, further comprising the step of providing a diffusion layer on the second layer to increase uniformity of emitted light.

60. The method of claim 40, wherein the step of placing the first layer of conductive ink comprises printing the first layer on a first side of the substrate, the method further comprising the steps of:

providing a phosphor-containing layer on a second side of the substrate, the first side being opposite to the second side of the substrate; and

printing a second layer of conductive ink on the phosphor-containing layer,

whereby the substrate is a dielectric layer.

61. The method of claim 40, wherein the substrate has a first and second side, the first side being opposite the second side of the substrate and wherein the method further comprise the steps:

providing a phosphor-containing layer on each side of the substrate,

the first layer of conductive ink being placed on the phosphor-containing layer on the first side of the substrate by printing; and

printing a second layer of conductive ink on the phosphor-containing layer on the second side of the substrate,

whereby the substrate is a dielectric.

62. The method of claim 40, further comprising the step of applying heat during the step of applying pressure to the substrate and conductive ink to further connect the conductive particles in the first layer and therefore increase electrical conductivity of the first layer.

63. A display having a self-illuminatable image, the display comprising:

a substrate;

a first layer of conductive ink printed on a first side of the substrate;

a phosphor-containing layer on an opposite side of the substrate; and

a second layer of conductive ink printed on the side of the substrate with the phosphor-containing layer,

whereby the substrate is a dielectric layer.

64. The display of claim 63, wherein the substrate is calendered before the printing of the first layer of conductive ink.

65. The display of claim 63, wherein the substrate is coated before printing of the first layer of conductive ink to thereby seal and smooth the substrate.

66. The display of claim 65, wherein the coating is at least one of calcium carbonate and kaolin.

67. The display of claim 63, wherein the substrate is paper, the paper containing at least one of titanium dioxide and barium titanate to increase dielectric constant.

68. The display of claim 67, further comprising a coating applied to the surface of the substrate, the coating increases electrical breakdown resistance.

69. The display of claim 68, wherein the coating is at least one of calcium carbonate and kaolin.

70. The display of claim 63, wherein the substrate is flexible paper.

71. The display of claim 70, wherein the paper has a thickness of 40 microns or less.

72. The display of claim 67, wherein the paper has a thickness of 10 microns or less.

73. The display of claim 63, further comprising another phosphor-containing layer on the first side of the substrate, the first layer of conductive ink being on the phosphor-containing layer on the first side of the substrate whereby an illuminatable display is provided on both sides of the substrate.

74. The display of claim 73, further comprising diffusion layers on both the first layer of conductive ink and the second layer of conductive ink to increase uniformity of emitted light.

75. The display of claim 63, further comprising a diffusion layer on the second layer of conductive ink to increase uniformity of emitted light.

107. The method of claim 63, wherein the display further comprises a first layer, a phosphor-containing layer and a second layer on both sides of the substrate, the substrate being a unitary, one-piece element.

108. The method of claim 63, wherein the display further comprises a first layer, a phosphor-containing layer and a second layer on both sides of the substrate, the substrate being two separate sheets of paper adhered together.

76. A display having a self-illuminatable image, the display comprising:

a substrate;

a first layer of conductive ink;

a second layer of conductive ink, at least a portion of the first layer being below a portion of the second layer such that the first and second layers overlap at portions of the image to be illuminated;

a phosphor-containing layer provided between the first and second layers of conductive ink;

a source for supplying an electrical current to both the first and second layers, phosphor in the phosphor-containing layer being excited to be illuminated in areas of the overlap between the first and second layers; and

a diffusion layer being provided above the second layer of conductive ink to increase uniformity of light emitted by the phosphor-containing layer.

77. The display of claim 76, wherein the first layer of conductive ink is printed on the substrate and wherein the substrate is calendered before the printing of the first layer of conductive ink.

78. The display of claim 76, wherein first layer of conductive ink is printed on the substrate and wherein the substrate is coated before printing of the first layer of conductive ink to thereby seal and smooth the substrate.

79. The display of claim 78, wherein the coating is at least one of calcium carbonate and kaolin.

80. The display of claim 76, wherein the substrate is paper.

81. The display of claim 80, wherein the diffusion layer includes at least one of calcium carbonate and kaolin.

82. The display of claim 76, further comprising at least one dielectric layer between the first layer and the phosphor-containing layer.

83. The display of claim 76, wherein the first layer is on one side of the substrate and the second layer is on an opposite side of the substrate whereby the substrate is a dielectric layer.

84. The display of claim 83, wherein the phosphor-containing layer is a first phosphor-containing layer and wherein the display further comprises a second phosphor-containing layer, the second phosphor-containing layer being on an opposite side of the substrate from the first phosphor-containing layer, whereby illuminatable images are provided on both sides of the substrate.

85. The display of claim 76, wherein the second layer of conductive ink is printed on the display in a predetermined pattern, the pattern comprising a series of crisscrossing lines or a strip having a plurality of openings provided therein.

86. A display having a self-illuminatable image, the display comprising:

a substrate;

a first layer of conductive ink;

a second layer of conductive ink, at least a portion of the first layer being below a portion of the second layer such that the first and second layers overlap at portions of the image to be illuminated;

a phosphor-containing layer provided between the first and second layers of conductive ink;

a source for supplying an electrical current to both the first and second layers, phosphor contained in the phosphor-containing layer being excited to be illuminated in areas of the overlap between the first and second layers; and

a smoothing layer being provided beneath the second layer to increase conductivity and minimize electrical resistance in the second layer, the smoothing layer providing a flat surface for printing the second layer whereby an amount of conductive ink for the second layer can be minimized.

87. The display of claim 86, wherein the first layer of conductive ink is printed on the substrate and wherein the substrate is coated before printing of the first layer of conductive ink to thereby seal and smooth the substrate.

88. The display of claim 87, wherein the coating is at least one of calcium carbonate and kaolin.

89. The display of claim 86, wherein the substrate is paper which is calendered to provide a flat surface whereby the amount of conductive ink for the first layer can be minimized.

90. The display of claim 89, wherein the paper is at least one of varnished, coated with aqueous coating and coated with ultraviolet curable coating to prevent absorption of the conductive ink of the first layer.

91. A method of making a display having a self-illuminatable image thereon, the method comprising the steps of:

providing a substrate;

printing a first layer of conductive ink in a first predetermined pattern on the substrate;

providing a phosphor-containing layer over the first layer of conductive ink;

printing a second layer of conductive ink above the phosphor-containing layer in a second predetermined pattern, the first predetermined pattern and the second predetermined pattern overlapping at portions of the image to be illuminated; and

minimizing an amount of conductive ink used in the second layer by providing a smoothing layer directly beneath the second layer, the smoothing layer providing a flat surface for printing of the second layer of conductive ink.

92. The method of claim 91, further comprising the step of minimizing electrical resistance in the second layer during the step of providing the smoothing layer.

93. The method of claim 91, further comprising the step of providing the same pattern for the first and second pattern.

94. The method of claim 91, wherein the step of printing the first layer comprises printing a series of lines in a first direction and wherein the step of printing the second layer comprising printing a series of lines in a second direction, the first direction being perpendicular to the second direction whereby the image includes a plurality of pixels.

95. The method of claim 91, further comprising the step of calendering the paper before the step of printing a first layer of conductive ink.

96. The method of claim 95, further comprising the step of coating the substrate before the step of calendering to thereby seal and smooth the substrate.

97. The method of claim 96, wherein the step of coating the substrate comprises applying at least one of calcium carbonate and kaolin to the substrate.

98. The method of claim 91, further comprising the step of increasing resolution of the image by coating the substrate before the step of applying the image.

99. The method of claim 98, wherein the step of coating further comprises the step of at least one of varnishing the substrate, coating the substrate with aqueous coating and coating the substrate with ultraviolet curable coating before the step of printing the first layer of conductive ink to thereby seal and smooth the substrate.

100. A two-sided display having a self-illuminatable image, the display comprising:

a first substrate;

a second substrate;

a first conductive layer between the first and second substrates;

a second top conductive layer on a side of the first substrate opposite to the first conductive layer; and

a second bottom conductive layer on a side of the second substrate opposite to the first conductive layer, the first substrate and the second substrate being joined and each substrate being a dielectric between the conductive layers.

101. The two-sided display of claim 100, wherein the first and second substrates are paper containing at least one of titanium dioxide and barium titanate to increase dielectric constant.

102. The two-sided display of claim 101, wherein the substrates are calendered before first conductive layer, the second top conductive layer and the second bottom conductive layer are applied thereto.

103. The two-sided display of claim 102, wherein the substrates have a coating of at least one of calcium carbonate and kaolin.

104. The two-sided display of claim 100, wherein the first conductive layer, the second top conductive layer and the second bottom conductive layer are conductive ink and wherein the first and second substrates are paper.