ELECTRO-OPTIC MEDIA PRODUCED USING INK JET PRINTING

Abstract

Ink jet printing can be used in the production of electro-optic displays for (a) forming a layer of a polymer-dispersed electrophoretic medium on a substrate; (b) forming a color electro-optic layer; (c) forming a color filter; and (d) printing electrodes and/or associated conductors on a layer of electro-optic material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A to 1E of the accompanying drawings are schematic side elevations showing various stages in the production of an active matrix electro-optic display of the present invention.

FIGS. 2A to 2E are schematic side elevations showing various stages in the production of a colored front plane laminate of the present invention.

FIGS. 3A to 3F are schematic side elevations showing various stages in the production of a double release film of the present invention.

Claims

1. A process for forming upon a substrate a layer of a two phase electrophoretic medium comprising a continuous phase and a discontinuous phase, the discontinuous phase comprising a plurality of droplets, each of which comprises a fluid and at least one particle disposed within the fluid and capable of moving through the fluid upon application of an electric field to the electrophoretic medium, the continuous phase comprising a polymeric material, the process comprising ink jet printing the electrophoretic medium on to the substrate.

2. A process according to claim 1 wherein the electrophoretic medium is ink jet printed with its continuous phase in a fluid form, and after printing of the electrophoretic medium, the electrophoretic medium is subjected to conditions effective to convert the continuous phase to a solid form, thereby forming a coherent layer of the electrophoretic medium on the substrate.

3. A process according to claim 1 wherein the substrate comprises a backplane comprising at least one pixel electrode.

4. A process according to claim 3 wherein the substrate comprises at least first and second pixel electrodes and wherein a first electrophoretic medium is ink jet printed on the first pixel electrode and a second electrophoretic medium, having at least one optical state different from all the optical states of the first electrophoretic medium, is ink jet printed on the second pixel electrode.

5. A process according to claim 4 wherein the first electrophoretic medium is ink jet printed on the first pixel electrode with its continuous phase in a fluid form, the first electrophoretic medium is subjected to conditions effective to convert the continuous phase to a solid form, thereby forming a coherent layer of the first electrophoretic medium on the first pixel electrode, and thereafter the second electrophoretic medium is ink jet printed on the second pixel electrode.

6. A process according to claim 1 wherein the substrate is provided with at least one fiducial mark and the printing of the electrophoretic medium is effected at least one predetermined location relative to the at least one fiducial mark.

7. A process according to claim 1 wherein the substrate is mounted at a predetermined location on a stage and the printing of the electrophoretic medium is effected at least one predetermined location relative to the stage.

8. A process for forming a front plane laminate having a color filter, which process comprises: providing a light-transmissive, electrically-conductive layer;ink jet printing a plurality of areas of colored material on to the light-transmissive, electrically-conductive layer, the plurality of areas including areas of at least two different colors;applying a layer of an electro-optic material over the colored material;applying a layer of a lamination adhesive over the layer of electro-optic material; andapplying a release sheet over the layer of lamination adhesive.

9. A process according to claim 8 wherein the colored material is ink jet printed in a fluid form, and is thereafter subjected to conditions effective to convert the fluid form to a solid form, thereby forming a coherent layer of the colored material on the light-transmissive, electrically-conductive layer.

10. A process according to claim 9 wherein a first colored material is ink jet printed in a fluid form, and is thereafter subjected to conditions effective to convert the fluid form to a solid form, thereby forming a coherent layer of the first colored material, and thereafter a second colored material is ink jet printed on the light-transmissive, electrically-conductive layer.

11. A process according to claim 8 further comprising ink jet printing at least one fiducial mark on the light-transmissive, electrically-conductive layer at least one predetermined location relative to at least one area of colored material.

12. A process for forming a color front plane laminate, which process comprises: (a) providing a light-transmissive, electrically-conductive layer;(b) ink jet printing a plurality of areas of electro-optic material on to the light-transmissive, electrically-conductive layer, the plurality of areas including areas of at least first and second types of electro-optic material, the second type of electro-optic material having at least one optical state different from all the optical states of the first type of electro-optic material;(c) applying a layer of a lamination adhesive; and(d) applying a release sheet over the layer of lamination adhesive,wherein steps (b) and (c) can be performed in either order.

13. A process according to claim 12 wherein step (b) is performed before step (c) so that the plurality of areas of electro-optic material are ink jet printed on to the light-transmissive, electrically-conductive layer, and the lamination adhesive is applied to the plurality of areas of electro-optic material.

14. A process according to claim 12 wherein step (c) is performed before step (b) so that the lamination adhesive is applied to the light-transmissive, electrically-conductive layer, and the plurality of areas of electro-optic material are ink jet printed on to the lamination adhesive.

15. A process according to claim 14 wherein, after the plurality of areas of electro-optic material have been ink jet printed on to the lamination adhesive, a second layer of lamination adhesive is applied to the plurality of areas of electro-optic material.

16. A process according to claim 12 wherein the electro-optic material is ink jet printed in a fluid form, and is thereafter subjected to conditions effective to convert the fluid form to a solid form, thereby forming a coherent layer of the electro-optic material on the light-transmissive, electrically-conductive layer.

17. A process according to claim 16 wherein a first colored material is ink jet printed in a fluid form, and is thereafter subjected to conditions effective to convert the fluid form to a solid form, thereby forming a coherent layer of the first colored material, and thereafter a second colored material is ink jet printed.

18. A process according to claim 12 further comprising ink jet printing at least one fiducial mark at least one predetermined location relative to at least one area of electro-optic material.

19. A process for forming a color double release film, which process comprises: (a) providing a first release sheet;(b) applying a first layer of a lamination adhesive to the release sheet;(c) ink jet printing a plurality of areas of colored material, the plurality of areas of colored material including areas of at least two different colors;(d) forming a layer of electro-optic material; and(e) providing a second layer of a lamination adhesive and a second release sheet over the layer of electro-optic material,wherein steps (c) and (d) are performed in either order.

20. A process according to claim 19 wherein step (e) is effected by forming the second layer of lamination adhesive on the second release sheet and thereafter laminating the second layer of lamination adhesive and the second release sheet to the remaining layers of the double release film.

21. A process for producing an electro-optic display, which process comprises: (a) providing a first release sheet;(b) applying a first layer of a lamination adhesive to the release sheet;(c) ink jet printing a plurality of areas of electro-optic material on to the first layer of lamination adhesive, the plurality of areas including areas of at least first and second types of electro-optic material, the second type of electro-optic material having at least one optical state different from all the optical states of the first type of electro-optic material; and(d) providing a second layer of a lamination adhesive and a second release sheet over the layer of electro-optic material.

22. A process according to claim 21 wherein step (d) is effected by forming the second layer of lamination adhesive on the second release sheet and thereafter laminating the second layer of lamination adhesive and the second release sheet to the remaining layers of the double release film.

23. A process for producing a laminate for use in the production of an electro-optic display, the process comprising: (a) providing a first release sheet;(b) ink jet printing a plurality of areas of colored material on to the first release sheet, the plurality of areas including areas of at least two different colors, thereby forming a first sub-assembly;(c) providing a second release sheet;(d) forming a layer of electro-optic material on the second release sheet, thereby forming a second sub-assembly; and(e) laminating the first and second sub-assemblies together with the areas of colored material in contact with the layer of electro-optic material to form the laminate.

24. A process according to claim 23 further comprising forming a layer of a lamination adhesive on a third release sheet, removing one of the first and second release sheets from the laminate produced in step (e), and contacting the layer of lamination adhesive with one of the plurality of areas of colored material and the layer of electro-optic material exposed by removal of the release sheet.

25. A process for producing a laminate for use in the production of an electro-optic display, the process comprising: (a) providing a first release sheet;(b) ink jet printing a plurality of areas of electro-optic material on to the first layer of lamination adhesive, the plurality of areas including areas of at least first and second types of electro-optic material, the second type of electro-optic material having at least one optical state different from all the optical states of the first type of electro-optic material, thereby forming a first sub-assembly;(c) providing a second release sheet;(d) forming a layer of a lamination adhesive on the second release sheet, thereby forming a second sub-assembly; and(e) laminating the first and second sub-assemblies together with the layer of lamination adhesive in contact with the plurality of areas of electro-optic material to form the laminate.

26. A process according to claim 25 further comprising forming a layer of a lamination adhesive on a third release sheet, removing the first release sheet from the laminate produced in step (e), and contacting the layer of lamination adhesive with the layer of electro-optic material exposed by removal of the first release sheet.

27. A process for forming an electro-optic display, which process comprises: providing a front plane laminate comprising a front substrate, a light-transmissive electrically-conductive layer, and a layer of electro-optic material;providing a backplane comprising at least one pixel electrode; andlaminating the front plane laminate to the backplane,wherein an adhesive material is ink jet printed on to a peripheral portion of at least one of the front substrate and the backplane prior to the lamination, the adhesive material forming an edge seal sealing the electro-optic material from the outside environment after the lamination.

28. A process for forming an electro-optic display, which process comprises: providing a backplane comprising at least one pixel electrode;ink jet printing an adhesive material on to a peripheral portion of the backplane;disposing on a central portion of the backplane lying within the adhesive material a front plane laminate comprising a front substrate, a light-transmissive electrically-conductive layer, and a layer of electro-optic material; anddisposing at least one protective layer over the front plane laminate, the at least one protective layer extending beyond the periphery of the front plane laminate and contacting the adhesive material, thereby forming an edge seal around the front plane laminate.

29. A process for forming an electro-optic display, which process comprises forming a layer of an electro-optic material on a substrate, and ink jet printing at least one pixel electrode or conductor on to the electro-optic material on the substrate.