Multilayered screens with light-emitting stripes for scanning beam display systems

• US 8,038,822 B2
• Filed: 05/19/2008
• Issued: 10/18/2011
• Est. Priority Date: 05/17/2007
• Status: Expired due to Fees

• Current Assignee: Prysm, Inc.
• Original Assignee: Prysm, Inc.
• Inventors: Ritter, John, Hajjar, Roger A., Malyak, Phillip H., Kent, David L., Kindler, David, Bukesov, Sergey A.
• Primary Examiner(s): Del Sole; Joseph
• Assistant Examiner(s): WU, VICKI H
• Application Number:
  US12/123,418
• Publication Number:
  US 20090116107A1
• Time in Patent Office: 1,247 Days
• Field of Search: 156/245
• US Class Current: 156/245
• CPC Class Codes: G02B 26/123 Multibeam scanners, e.g. using multiple light sources or beam splitters
• CPC Class Codes: G03B 21/005 Projectors using an electronic spatial light modulator but not peculiar thereto
• CPC Class Codes: G03B 21/567 for colour projection G03B21/58, G03B21/60 take precedence
• CPC Class Codes: G03B 33/06 by additive-colour projection apparatus
• CPC Class Codes: H04N 9/3129 scanning a light beam on the display screen scanning a light beam on a screen in displays other than projection devices G09G3/02; scanning systems in general G02B26/10; projectors using laser light sources in general H04N9/3161
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina

Abstract

Multilayered screens with parallel light-emitting stripes for scanning beam display systems. The light-emitting materials may include phosphor materials and non-phosphor materials.

Claims

1. A method for making a display screen, comprising:

applying light-emitting materials, that absorb excitation light at an excitation wavelength to emit visible light at wavelengths different from the excitation wavelength, into parallel grooves of a mold so that two adjacent grooves are applied with two different light-emitting materials that emit at two different wavelengths;

controlling a volume of each light-emitting material in each respective groove during the process of applying the light-emitting materials into the mold to partially fill each groove;

applying a liquid material in each groove on top of a respective light-emitting material to fill the groove;

transforming the liquid material into a transparent solid material that attaches to each light-emitting material in each groove;

placing a screen layer on the mold to be in contact with and to engage to the transparent solid material;

lifting the screen layer to lift a stripe formed by the transparent solid material and each light-emitting material out of the mold to form a light-emitting layer of parallel light-emitting stripes; and

applying one or more additional screen layers to the light-emitting layer to form a display screen.

2. The method as in claim 1, wherein:

the liquid material is a UV-curable material, and

UV light is directed to the liquid material to cure the liquid material in forming the transparent solid material.

3. The method as in claim 1, wherein:

the liquid material is a heat-curable material, and

heat is applied to the liquid material to cure the liquid material in forming the transparent solid material.

4. The method as in claim 1, comprising:

after lifting the light-emitting layer of parallel light-emitting stripes out of the mold, coating a metal layer over the light-emitting stripes to cover exposed surfaces of the light-emitting material and the transparent solid material and a surface over the screen layer between two adjacent light-emitting stripes; and

applying a filler material to fill gaps between two adjacent light-emitting stripes;

removing part of the filler material, the metal layer on top of the light-emitting material and a part of the light-emitting material to form a flat surface that exposes the light-emitting material in each light-emitting stripe; and

applying another screen layer over the flat surface.

5. The method as in claim 4, wherein:

the part of the filler material, the metal layer on top of the light-emitting material and the part of the light-emitting material are removed to leave surface textures on an exposed surface of the light-emitting material so that air gaps are formed between the light-emitting material and the screen layer engaged on the flat surface.

6. The method as in claim 4, wherein:

the filler material is a black material that absorbs light.

7. The method as in claim 1, comprising:

after lifting the light-emitting layer of parallel light-emitting stripes out of the mold, filing gaps between adjacent light-emitting stripes with a reflective material to cover exposed surfaces of the light-emitting material and the transparent solid material; and

removing part of the reflective material on top of the light-emitting material and a part of the light-emitting material to form a flat surface that exposes the light-emitting material in each light-emitting stripe; and

applying another screen layer over the flat surface.

8. The method as in claim 7, wherein:

the part of the reflective material on top of the light-emitting material and the part of the light-emitting material are removed to leave surface textures on an exposed surface of the light-emitting material so that air gaps are formed between the light-emitting material and the screen layer engaged on the flat surface.

9. The method as in claim 1, comprising:

treating inner surfaces of the grooves in the mold prior to applying the light-emitting materials to facilitate separation of each light-emitting stripe from the mold.

10. The method as in claim 9, wherein:

the inner surfaces of each groove are coated with a layer of nickel.

11. The method as in claim 9, wherein:

the inner surfaces of each groove are coated with a layer of a surface lubrication material.

12. The method as in claim 9, wherein:

the inner surfaces are coated with a layer of nickel.