Electroluminescent structure and method for deploying the same

Electroluminescent structure and deployment method thereof

<p>102. . . Transfer release paper</p><p>104. . . Encapsulation layer</p><p>105. . . boundary</p><p>106. . . Translucent electrode layer</p><p>107. . . Front bus</p><p>108. . . Luminous layer</p><p>110. . . Dielectric layer</p><p>112. . . Back electrode layer</p><p>114. . . Encapsulation layer</p><p>116. . . Adhesive layer</p><p>118A. . . Rear contact window</p><p>118B. . . Front contact window</p><p>300. . . Membrane electroluminescent lamp</p><p>401. . . Flexible bus</p><p>402. . . Connector</p><p>403. . . Contact point</p><p>501. . . Tail printing bus</p><p>601. . . Resection</p><p>602B, G, W. . . Electroluminescent section</p><p>603B, P, R, X. . . Section</p><p>620. . . Transition section</p>

For a more complete understanding of the present invention and its advantages, reference will now be made to the accompanying drawings in which:

Figure 1 is a cross-sectional view showing a preferred embodiment of a film-shaped EL lamp according to the present invention;

Figure 2 is a perspective view of the sectional view of Figure 1;

Figure 3 is a perspective view showing the film-shaped EL lamp of the present invention being peeled off from the transfer release paper 102;

Figure 4 shows a preferred method of supplying power to the membranous EL lamp of the present invention;

Figure 5 shows another preferred method of supplying power to the film-shaped EL lamp of the present invention;

Figure 6 shows sections of a film-like EL lamp 300 with a cut-away portion 601 that supports the various layering techniques described herein to form a selected unlit/lit appearance.

Related application

The case is filed on October 11, 2000, the date of application of US Provisional Application No. 06239,507.

The present application is further related to the commonly assigned U.S. Patent Application "including a metal/metal oxide dopant suspended in a translucent layer of a gel resin", Application No. 09/173,521, filed on October 15, 1998 U.S. Patent No. 6,261,633, the disclosure of which is incorporated herein by reference.

This application is also related to the commonly assigned U.S. Patent Application "Method of Constructing Elastomeric Electroluminescent Luminaires", Application No. 09/173,404, filed on October 15, 1998, and now in U.S. Patent No. 6,270,834. Its disclosure is incorporated herein by reference.

Technical field of invention

Briefly, the present invention relates to electroluminescent systems, and more particularly to a film-like, one-piece urethane electroluminescent structure comprising a series of continuous electroluminescent layers using a single piece of ethylene condensation. The gum resin carrier is deployed and the carrier is converted to a one-part urethane carrier during aging.

Background of the invention

Electroluminescence ("EL") has been known for many years as a light source and relatively low power illumination. Since electroluminescent lamps have such properties, electroluminescent lamps are commonly used today to provide display lights such as automobiles, airplanes, watches, and laptops. One such electroluminescent use is to provide the backlight required for a liquid crystal display (LCD).

An electroluminescent lamp is typically characterized by a "lossy" parallel plate capacitor having a layered configuration. Currently, electroluminescent lamps in the industry generally comprise a dielectric layer and a light-emitting layer separating two electrodes, at least one of which is translucent such that light emitted by the luminescent layer can pass therethrough. The dielectric layer gives the lamp a capacitive nature. The luminescent layer is energized by a suitable power supply, typically about 115 volts alternating current oscillating at about 400 Hz, which is preferably provided by a dry battery powered inverter. However, electroluminescent lamps are known to operate in the 60 volt to 500 volt ac voltage range and in the 60 Hz to 2.5 kHz oscillation range.

The industry standard translucent electrode consists of a "spray" polyester film with indium-oxide (ITO). Polyester films that are typically sputtered with ITO can be used as electrodes for providing suitable conductive properties to useful translucent materials.

A disadvantage of using such a polyester film process is that the shape and size of the final electroluminescent lamp is greatly limited by the size and shape that can be produced by the ITO-coated polyester film. A further design factor for the use of ITO sputter films is the need to balance the electrical resistance (and thus the resulting light/power loss) caused by the ITO film serving the region with the predetermined electroluminescent area. Typically a large area electroluminescent layer requires a low resistance ITO film to maintain manageable power consumption. Such an ITO sputter film must be fabricated to meet the specific luminaire requirements that the film will use. This complicates the manufacturing process of the luminaire, increases the lead time of the conventional ITO sputtering film, and limits the size and shape of the luminaire that can be manufactured. In addition, the use of ITO sputtering films tends to increase the manufacturing cost of non-standard shaped electroluminescent lamps.

Other layers of electroluminescent lamps used in the industry are suspended in a variety of different carrier compounds (commonly known as "vehicles"), which are typically chemically distinct from one another. As detailed later, the superposition of such carrier compounds on one another and on the sputtered ITO polyester film pose particular problems in the manufacture and performance of the luminaire.

The electroluminescent layer typically comprises a cellulose based resin in which the electroluminescent level phosphorus is suspended in a liquid form. In various processes, this suspension is applied over a sputtered ITO layer on a translucent electrode polyester. The individual electroluminescent grade phosphorous crystallites typically have a relatively large particle size, thus providing phosphor particles of sufficient size to emit strong light. However, such a particle size solution causes the suspension to become uneven. In addition, the relatively large size of the phosphor particles may cause the light emitted by the electroluminescent lamp to be grainy.

The dielectric layer typically comprises a suspension of titanium dioxide and barium titanate suspended in a cellulose based resin, also in liquid form. Continuing the exemplary process described above, such suspensions are typically applied over the electroluminescent layer. It should be noted that in order to achieve better illumination, the electroluminescent layer usually separates the translucent electrode from the dielectric layer, but the industry must understand the necessary requirements for the function of the non-electroluminescent lamp. Some unusual design criteria may require the dielectric layer to separate the electroluminescent layer from the translucent electrode. It is also important to note that the phosphor and dielectric layers used in the industry utilize polyester based resins as carrier blends rather than the more typical cellulose based resins discussed above.

The second electrode is typically opaque and comprises a conductor such as silver and/or graphite typically suspended in an acrylic or polyester support.

A disadvantage of the industry's use of such liquid-based carrier compound standards is that the suspension molecules are quite heavy resulting in rapid separation of the suspension. It is necessary to constantly agitate the liquid solution to maintain the suspension. Such agitation demands add additional manufacturing steps and introduce variables to the quality of the suspension. In addition, industry standard liquid carrier blends are highly volatile and produce hazardous or hazardous fumes. As a result, the current system is expected to cause evaporation losses in a work environment that improves worker safety.

Another disadvantage of combining different carrier blends as is known in the art is that the bonding between the layers and the transition are quite intense. The intense transition between the layers tends to leave the layer when the assembly is bent or the assembly is exposed to extreme temperature changes.

Yet another disadvantage of combining different carrier compounds is the different processing and application requirements for each layer. It is to be understood that the various layers of the electroluminescent lamp must be formed using different techniques including mixing, application and curing techniques. This variety of manufacturing techniques complicates the process, thus affecting manufacturing costs and product performance.

The disclosure of the application Serial No. 09/173,521, the disclosure of which is incorporated herein in A variety of the aforementioned needs of the lighting industry. Such a vinyl-based, one-piece construction is also disclosed in the specific embodiment of the membranous electroluminescent device taught in the application Serial No. 09 173, 404, the disclosure of which is incorporated herein by reference. In particular, 09 173,404 teaches the use of a one-piece structure based on a vinyl resin as an electroluminescent laminate disposed between two layers of film-like urethane encapsulating layers.

It is found that the electroluminescent system described in the application Nos. 09, 173, 521 and 09, 173, 404 is useful, and it is understood that the electroluminescent laminate of the application No. 09-173, 404 can be suspended in a urethane carrier. A further advantage of obtaining a one-piece structure. In this manner, the film-like electroluminescent device disclosed in 09/173,404 comprises a multilayer of electroluminescent laminates in a one-piece unit surrounded by a urethane encapsulating layer.

However, it should be understood that urethane is not the most desirable carrier for electroluminescent systems in terms of manufacturing and deployment. The urethane lacks a plurality of vinyl resin gel media disclosed in the application No. 09,173,521. advantage. There is a need in the art for an electroluminescent system that can be constructed using a single piece of conventional carrier comprising a vinyl based resin in the form of a gel, followed by obtaining a one-piece unit having a urethane encapsulating layer when the carrier is cured, for example Revelation of Application No. 09/173,404.

Summary of invention

The present invention solves the problem by suspending a selected layer of a film-like electroluminescent system in a carrier comprising (1) a vinyl-based carrier in the form of a gel and (2) a polymer hexamethylene diisocyanate catalyst. The aforementioned problem. During the ripening process, the catalyst helps to convert the vinyl resin carrier into a urethane. Once matured, the converted urethane carrier blend combines the electroluminescent layer into a one-piece structure that also includes other urethane layers such as encapsulation layers. As a result, the film-like electroluminescent structure produced in accordance with the present invention is even more powerful and less prone to delamination than its precursor structure. Highly crosslinkable between adjacent urethanes.

As described above, the preferred embodiment of the present invention initially uses a vinyl-based resin in the form of a gel as a one-part carrier blend during the deployment of the ink of the present invention. The choice of such a carrier is unexpectedly contrary to the teachings of the prior art. As mentioned previously, functional electroluminescent lamps require a dielectric layer to achieve capacitive properties. A vinyl-based resin is not often used as a dielectric material, so that a vinyl-based resin is used and the intuition is violated. The choice of such a carrier further confirms and is somewhat surprisingly compatible with a wide variety of substrates including metal, plastic and cloth fabrics. Furthermore, unlike conventional carrier materials, vinyl based gels are highly compatible with well known manufacturing techniques such as screen printing.

Thus, the present invention retains these and other advantages of deploying electroluminescent inks to vinyl gel resins. Once deployed, the catalyst is added to the vinyl resin-based ink to convert the vinyl to the urethane, and the cured laminate can be highly interspersed between the converted ink layer and the other successive urethane layers. Union. Such high cross-linking occurs between adjacent mature urethane layers and is independent of the urethane layer as a urethane or as a catalyzed vinyl resin.

One application of the preferred embodiment is for the apparel industry. It is to be understood that the film-like electroluminescent system disclosed herein can be applied to a transfer release paper or a coated polyester sheet by a conventional screen printing technique to constitute a film-type "transfer". The proper adhesion of a suitable adhesive to a variety of garments and garments will result in a virtually infinite shape, size and variation to a robust electroluminescent design. This application differs from previously known garment applications in that pre-fabricated electroluminescent lamps of a predetermined shape and size are combined and secured to the garment by stitching, gluing or the like. It will be understood, however, that the present invention is distinct from such techniques, and that the present invention does not resemble prior systems, using apparel fabrics as substrates for electroluminescent systems.

It should also be understood that the invention is not limited to clothing use. As shown, the present invention is compatible with a wide variety of substrates and can be made into numerous further applications including, but not limited to, emergency lighting, instrument lighting, LCD backlighting, information displays, key pads for cellular phones, backlit keyboards, and the like. In fact, the highly recommended applications of the present invention have historically required passive ink application to the substrate for information or visual design, which can now be used to enhance or replace information with electroluminescence.

It is further understood that the industry's accessory standards can be combined with the present invention to further expand its range of applications. For example, dyes and/or filters can be applied to substantially obtain any color. In addition, a timer or sequencer can be applied to the power supply for delay or other time effects.

It is further understood that although preferred embodiments of the invention relate to the use of screen printing techniques, virtually any of a variety of methods of application are suitable. For example, each layer may be applied to the substrate by a pressurized spray of a nozzle that is not in contact with the substrate. It is further noted that the layers of the electroluminescent system embodying the present invention in accordance with the present invention may even be applied in a manner different from adjacent layers.

Thus, the technical advantage of the present invention is that the ink of the present invention has the advantage of being in the form of a gel-form vinyl resin during deployment, and has the advantage of having a urethane ink after aging. Although formulated in a vinyl form, the matured adjacent layers of the invention are catalyzed and converted to the urethane form resulting in a strong bond to each other and to a surrounding urethane layer such as an encapsulating layer. Such strong bonding also becomes feasible via the fabrication of the final form of the one-piece carrier and cross-linking via the urethane layer. As a result, the one-piece structure of the present invention obtained is highly strong. The resulting one-piece structure is also in the form of a film, and has all the advantages of the film-like structure disclosed in the application No. 09 173,404. Another technical advantage of the present invention is that a single-piece vinyl-based resin carrier in the form of a gel is used for a plurality of layers by preliminary use, which makes the manufacturing process simple and thus reduces the manufacturing cost. In a preferred embodiment of the invention, only a single carrier mix is required to be purchased and processed. In addition, since the layers are applied by a similar method, the application of the layers and the treatment of the materials include the simple cleaning of the equipment, the conditions required for the ripening are similar and can be cleaned using the same solvent.

Still another technical advantage of the present invention is that the initial carrier is a gel which, after preliminary mixing, maintains the non-catalytic component complete suspension for a long period of time. It will be appreciated that such maintenance suspension will reduce manufacturing costs because the various components will not settle out of the suspension and thus eliminate the need for re-agitation.

In addition, the initial gel carrier reduces spillage because the gel is less volatile than the carrier compounds conventionally used in the industry. Sprinkling is further reduced by the aforementioned extended suspension life. At present, the industry needs to constantly agitate the volatile carrier compound to easily cause vaporization of the carrier mixture. Gasification of the carrier mix can be reduced by eliminating the need for frequent agitation.

The features and technical advantages of the present invention will be more fully understood from the foregoing description. Other features and advantages of the present invention will be described hereinafter, which will form the subject of the patent application scope of the invention. Those skilled in the art will appreciate that the conception and specific embodiments disclosed are susceptible to modification and design of other structures for the purpose of carrying out the invention. At the same time, skilled artisans are also to be aware of the considerable construction of the invention and the scope of the invention as set forth in the accompanying claims.

Simple illustration

For a more complete understanding of the present invention and its advantages, reference will now be made to the accompanying drawings in which:

Figure 1 is a cross-sectional view showing a preferred embodiment of a film-shaped EL lamp according to the present invention;

Figure 2 is a perspective view of the sectional view of Figure 1;

Figure 3 is a perspective view showing the film-shaped EL lamp of the present invention being peeled off from the transfer release paper 102;

Figure 4 shows a preferred method of supplying power to the membranous EL lamp of the present invention;

Figure 5 shows another preferred method of supplying power to the film-shaped EL lamp of the present invention;

Figure 6 shows sections of a film-like EL lamp 300 with a cut-away portion 601 that supports the various layering techniques described herein to form a selected unlit/lit appearance.

DESCRIPTION OF THE PREFERRED EMBODIMENT

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional view showing a preferred embodiment of an EL lamp in a film-like structure according to the present invention. Figure 2 is a perspective view of Figure 1. It can be seen that the layers of Figures 1 and 2 are all disposed on the transfer release paper 102. In a preferred embodiment, the transfer release paper is an Aquatron release paper manufactured by Midland Paper. It is also necessary to know alternative papers, for example, a transfer release film or a ruthenium-coated polyester sheet according to the present invention. In addition, the EL lamp can be directly deployed on a permanent substrate.

Subsequent layers as shown in Figures 1 and 2 (and subsequent figures) are preferably deployed by screen printing methods known in the art. However, it is to be understood again that the present invention is not limited to simply applying a film-like EL lamp of each layer by screen printing, and other methods may be used to constitute the film-shaped EL lamp of the present invention.

The first encapsulation layer 104 is printed on the transfer release liner 102. The first encapsulation layer 104 is preferably printed as a plurality of intermediate layers to achieve the desired total combined thickness. Printing the first encapsulation layer 104 into a series of multi-layered intermediate layers also helps to dye or color the particular layer to achieve the desired natural light appearance of the EL luminaire. Preferably, but not necessarily, the first encapsulating layer 104 is a polyurethane such as Nazdar DA170 in a ratio of 3:1 to the catalyst DA176. A commercially available polyurethane ink intended to be commercially available. As noted above, such polyurethanes have predetermined film characteristics of the encapsulating layer, are chemically stable with other components of the EL lamp, and are also extremely flexible and malleable. Such polyurethanes can be further printed into multiple layers to achieve a one-piece final thickness upon aging. Finally, such polyurethanes are substantially colorless and generally transparent, and thus the layers are further suitably adapted to be subjected to dyeing or other coloring treatment (described in detail later) to provide EL lamps. The luminaire is designed in natural light to complement its active illuminating appearance under soft light.

Referring back to Figures 1 and 2, the first encapsulation layer 104 is printed on the transfer release liner 102 such that the border 105 does not contain the edges of the EL system layers 106-112. This provides a section in which the second encapsulation layer 114 can be bonded and completely sealed with the crosslinked EL system, as will be described in more detail below.

Next, the EL system is printed on the first encapsulation layer 104. It can be seen from Figures 1 and 2 that the EL lamp is formed in a face-down manner. According to the present invention, one or more layers, and preferably all of the layers including the semi-transparent electrode layer 106, the light-emitting layer 108, the dielectric layer 110, and the back electrode layer 112 are deployed as active ingredients (hereinafter also referred to as "doping agents"). It is initially a one-piece vinyl resin carrier suspended in a gel form. It will be understood that although the preferred embodiment herein discloses the use of a one-piece vinyl-based gel carrier in which all of the layers are suspended, other embodiments of the invention may also have not all of the adjacent layers suspended therein.

It is necessary to understand the preliminary deployment of the vinyl resin in which the dopant is suspended in the form of a gel. As a result, the manufacturing cost can be reduced by purchasing a larger amount of the carrier and storing, mixing, treating, curing and cleaning a similar suspension.

Studies have also shown that the initial use of a carrier in the form of a gel provides further advantages. The viscosity and encapsulation properties of the gel result in better suspension of the particulate dopant when mixed with the gel. Such suspension improvement allows the agitation of the mix to maintain the frequency required for the suspension of the dopant to be reduced. Experiments have shown that less agitation results in less spillage of the mix during the process.

Further, the vinyl-based resin in the gel form is less volatile and less toxic than the liquid-based cellulose used in the prior art, based on acrylic and polyester resins. In a preferred embodiment of the invention, the vinyl based gel used as a one-piece carrier is an electronic grade vinyl based gel such as SS24865 from Acheson. The vinyl-based ink in the form of an electronic grade gel maintains substantial complete suspension of the particulate dopant throughout the manufacturing process. In addition, such electronic grade vinyl inks are ideally suited for use in laminate applications using industry standard screen printing techniques.

According to the present invention, once the vinyl-based gel resin carrier has been doped with a specific active component to form an ink, depending on the content of the vinyl-based gel resin of the ink, the catalyst may be mixed according to the amount determined by the content of the vinyl-based gel resin of the ink. Into the ink. Such a catalyst facilitates the conversion of the vinyl carrier to the carbamate during aging. Referring again to FIG. 1 and also to FIG. 2, when the EL layers 106, 108, 110, and 112 are cured, the adjacent urethane layers are cross-linked to each other and cross-linked to the surrounding encapsulant layers 104 and 114 to the amine-based group. The laminate product in the form of an acid ester provides enhanced one-piece properties. The laminate of the urethane form also has a film-like nature with a high degree of flexibility, as taught by U.S. Patent Application Serial No. 09,173,404.

Preferred catalysts for use in the specific embodiments disclosed herein are polyisocyanates based on 1,6-hexamethylene diisocyanate, also referred to as polymer hexamethylene diisocyanate from the aliphatic polyisocyanate group of polymers. . Such use will be referred to as "PHD" when it is used hereinafter as a catalyst for the preferred embodiment of the present invention. PHD is available from Bayer on the market under the trade name Desmodur N-100 product code D-113. However, it should be understood that the present invention is not limited to PHD as a catalyst, and any catalyst having the same catalytic properties as PHD converting ethylene to urethane can be used with the same effect.

Referring again to Figures 1 and 2, the semi-transparent electrode layer 106 is first printed onto the first encapsulation layer 104. The translucent electrode 106 comprises a suitably translucent electrical conductor in the shape of a single piece of carrier doped particles. In a preferred embodiment of the invention, the dopant is indium-tin-oxide (ITO) in powder form.

The design of the semi-transparent electrode layer 106 is referred to a number of variables. It is to be understood that the effectiveness of the translucent electrode layer 106 is affected not only by the concentration of ITO used, but also by the ratio of indium-oxide to tin of the ITO dopant itself. The factors such as the size of the electroluminescent lamp and the power available must be considered when determining the exact ITO concentration to be used by the semi-transparent electrode layer 106. The more ITO is used in the mixture, the higher the conductivity of the semi-transparent electrode layer 106 becomes. However, it is necessary to sacrifice the semi-transparent electrode layer 106 to become less translucent. The electrode becomes less translucent and requires more power to produce sufficient electroluminescence. In this regard, the higher the conductivity of the conductive translucent electrode layer 106, the lower the overall resistance of the EL system 106-112, and thus the lower the power required to generate electroluminescence . It is therefore important to understand that the ratio of indium-oxide to tin in ITO, the concentration of ITO in suspension, and the total layer thickness must be carefully balanced to achieve performance that meets design specifications.

Experiments have shown that a 25% to 50% by weight ITO powder containing 90% indium-oxide and 10% tin with a 50% to 75% electronic grade gel-like vinyl ink suspension is applied by screen printing to a thickness of about 9 microns. At the time, the result is that the translucent electrode layer 106 is obtained for most purposes. Preferably, the ITO powder is mixed with the vinyl gel in a ball mill for about 24 hours. ITO powder is available from Arconium, while vinyl powder is still available from Acheson as SS24865. Further, an appropriately premixed ITO ink is available from the Acheson Company under the trade name EL020 in the form of a vinyl gel. It is further understood that the semi-transparent electrode layer 106 dopant is not limited to ITO, but may be any other conductive dopant having translucent properties.

The catalyst is added to the ITO ink after ball milling according to the present invention, or the additional catalyst is directly added to the ink if it is obtained in a premixed manner. Preferably, the amount of catalyst required by weight is directly agitated into the ink using polypropylene blades or scoops. Stirring is continued until the microscopic bottom of the catalyst is dispersed to the ink.

The catalyzed ink can then be deployed into a translucent electrode layer 106 using screen printing or other suitable method. Unused catalyzed ink must be refrigerated at about 5 °C. When used for refrigeration, such unused ink can be used for several days after the initial addition of the catalyst.

The amount of catalyst added varies with the ink composition of the ITO and vinyl resin carriers. Although it is necessary to experiment to achieve the best results when the ITO powder ball is ground into the vinyl gel, the optimum weight of the PHD catalyst is 3% by weight of the electronic grade vinyl ink (such as the Acheson SS24865) used in the ball milled mixture. 5% by weight range. In addition, using the "shortcut" of the premixed ink, it was found that the work effect was achieved by adding PHD to the Acheson premixed ITO ink product EL020 in a ratio of 0.45 g PHD to 100 g premixed luminescent ink product.

Referring to Figures 1 and 2, it should be understood that the front busbar 107 (shown in Figures 1 and 2) is deployed in the semi-transparent electrode layer 106 to provide electrical contact between the translucent electrode layer 106 and a power source (not shown). . In a preferred embodiment, the front bus bar 107 contacts the semi-transparent electrode layer 106 after the semi-transparent electrode layer 106 is disposed on the first encapsulation layer 104. Although not specifically required by the present invention, experiments have shown that the current busbar 107 is deployed on top of the translucent electrode layer 106 rather than the opposite (the semi-transparent electrode layer 106 is deployed on top of the front busbar 107) with improved performance. The reason is that when the semi-transparent electrode layer 106 is disposed on top of the front bus bar 107, it is found that the semi-transparent electrode layer 106 is matured to form a barrier to inhibit conduction of the previously laid front bus bar 107. This phenomenon does not occur in the opposite case, so the front bus bar 107 is preferably deployed on top of the translucent electrode layer 106.

If the front bus bar 107 is a thin metal row, it is also preferred, but not necessary, to apply the front bus bar 107 to the semi-transparent electrode layer 106 prior to curing, so that the front bus bar 107 becomes part of the one-piece structure of the present invention, Electrical contact between the front bus bar 107 and the semi-transparent electrode layer 106 is optimal. However, in other embodiments, the front busbar 107 can be an ink that is deployed by screen printing or other suitable method. In this case, the ink can be formulated and deployed as described later for the back electrode layer 112. However, it has been found that the use of the catalyst in the front bus bar ink does not actually exert its effect as described later with reference to the back electrode layer 112. The electrode content of the ink becomes excessively reacted, with the result that the ink becomes unusable after only a few minutes.

A luminescent layer 108 (preferably a phosphorus/barium titanate mixture) is then printed on the translucent electrode layer 106 and printed on the front busbar 107. The luminescent layer 108 comprises phosphorus in a one-piece carrier doped electroluminescent grade package. Experiments have shown that a suspension containing 50% by weight phosphorus to 50% gel form electronic grade vinyl ink can be obtained with a useful luminescent layer 108 when applied to a thickness of about 25 to 35 microns. Preferably, the phosphorus is mixed with the vinyl gel for about 10-15 minutes. The mixing method preferably employs a method of minimizing damage to individual phosphorus particles. The appropriate phosphorus is available from Osram Sylvania and the vinyl gel is still SS24865 from the Acheson Company.

It is to be understood that the luminescent color is determined by the phosphor color used by the luminescent layer 108, and the dye can be further modified. A dye-mixed vinyl-based gel having a predetermined color before being added to phosphorus is preferred. For example, the addition of rhodamine to the vinyl gel of the luminescent layer 108 results in white light.

Experiments have shown that a suitable mixture such as barium titanate can improve the efficacy of the luminescent layer 108. As described above, the particle structure of the mixture such as barium titanate is smaller than that of the electroluminescent phosphor particles suspended in the light-emitting layer 108. As a result, the mixture easily harmonizes the consistency of the suspension, making the luminescent layer 108 more uniform, and the auxiliary phosphorus uniformly distributed in the suspension. The smaller the mixture particles, the lighter diffuser, which corrects the granular appearance of the luminescent phosphor. Finally, experiments have shown that the barium titanate mixture actually enhances the phosphorous luminosity at the molecular level via stimulating the photon emissivity.

The preferred embodiment uses a barium titanate mixture with barium titanate used in the dielectric layer 110, as described in more detail below. As described later, such barium titanate can be obtained in powder form from Tam Ceramics. The re-ethylene based gel carrier was SS24865 from the company of Acheson. In a preferred embodiment, barium titanate is premixed in a vinyl gel carrier, preferably in a 70% by weight ratio of ethylene gel to 30% barium titanate. This mixture was mixed for at least 48 hours in a ball mill. In addition, a pre-mixed barium titanate luminescent ink in the form of a vinyl gel can be obtained from Acheson Corporation under the product names EL035, EL035A and EL033. If the luminescent layer 108 is to be dyed, the dye needs to be added to the vinyl-based gel carrier prior to mixing in the ball mill.

In a one-part urethane embodiment, the catalyst is added to the luminescent ink after ball milling (whether or not loaded with barium titanate) or, if otherwise pre-mixed, the catalyst is added directly to the ink. As with the ITO inks described above, it is preferred to use a polypropylene blade or spoon to manually infuse the ink by weight. Stirring was continued until the catalyst microbase was dispersed to the ink by visual inspection.

The ink to which the catalyst is added is then deposited into the luminescent layer 108 using screen printing or other suitable method. As noted above, the unused catalyzed ink can be refrigerated and reused for several days with no noticeable loss in performance.

The amount of catalyst added was again changed with the ink composition of the phosphorus and vinyl resin carrier. Although the experiment is required to obtain the most desirable results when the phosphorus powder (with or without barium titanate) is ball milled into the vinyl gel, the optimum weight of the PHD catalyst is again based on the electronic grade vinyl ink used in the ball mill mixture (eg sub- The cesium SS24865) weight range of 3% to 5% by weight. In addition, as a "shortcut" using a premixed barium titanate luminescent ink, it was found that it is useful to add PHD to the Acheson premixed luminescent ink products EL035, EL035A and EL033 by adding 0.22 gram of PHD to 100 gram of EL020. effect.

Referring back to Figures 1 and 2 again, dielectric layer 110 (preferably barium titanate) is printed on luminescent layer 108. Dielectric layer 110 comprises a dielectric in the form of a single piece of carrier mashed particles. In a preferred embodiment, the dopant is a barium titanate powder. Experiments have shown that it is useful to apply a suspension containing 50% to 75% by weight of barium titanate powder to 50% to 25% by weight of a gel-form electronic grade vinyl ink by screen printing to a thickness of about 15 to 35 microns. Dielectric layer 110. The barium titanate is preferably mixed with a vinyl gel in a ball mill for about 48 hours. Suitable barium titanate powders are available from Tan Ceramics, Inc., and vinyl gels may be SS24865 from Acheson, as previously described. Further, a premixed barium titanate ink suitably in the form of a vinyl gel can be obtained from Acheson Corporation under the product name EL040. It is further understood that the dopant of dielectric layer 110 can be selected from other dielectric materials, either individually or in mixtures. Such other materials include titanium dioxide or mylar, teflon or polystyrene derivatives.

In a one-part urethane embodiment, the catalyst is added to the dielectric ink after ball milling, or otherwise added to the ink if obtained in a premixed form. As with the inks described above, the desired amount of catalyst by weight is preferably mixed into the ink by hand using polypropylene blades or scoops. The agitation was continued until the macroscopic bottom of the catalyst was dispersed to the ink.

The catalyzed ink is then deployed as a dielectric layer 110 using screen printing or other suitable method. As noted above, the unused catalyzed ink can be refrigerated and re-used for several days with no noticeable loss in performance.

The addition weight of the re-catalyst is changed depending on the ink composition of the dielectric dopant and the vinyl resin carrier. Although experiments are needed to obtain the best results when ball-wounding agents such as barium titanate are ball milled into vinyl gels, the optimum weight of PHD catalysts for ball-milling mixtures is still electronic grade vinyl inks (eg, Acheson). SS24865) 3% to 5% by weight range. In addition, using the "shortcut" of the premixed dielectric ink, it was found that an effective result was obtained by adding PHD to the Acheson premixed dielectric ink product EL040 at a ratio of 0.345 g PHD to 100 g EL040.

It has also been found that the addition of urethane to the dielectric ink to be deployed as dielectric layer 110 further "strengthens" the electroluminescent structure of the present invention. For example, a urethane such as Nazda product DA170 "transparent T grade" polyurethane can be added to the Acheson premixed dielectric ink product EL040. The DA170 transparent T-grade polyurethane additive was first mixed with a DA176 catalyst in a ratio of about 3 parts of polyurethane to 1 part of catalyst. The catalyzed additive is then mixed with EL040 after the dielectric ink has been mixed with the PHD catalyst. The polyurethane additive can be mixed with a dielectric ink in a ratio of 25% additive 75% ink to 75% additive 25% ink range, measured by weight before adding any catalyst (DA176 or PHD).

The addition of the urethane to the dielectric ink can greatly improve the mechanical strength of the dielectric layer 110 after deployment and aging of the dielectric layer. Crosslinking of the dielectric layer 110 with the adjacent urethane layer is also improved. Further, the urethane content tends to reduce the tendency of the dielectric layer 110 to collapse. The higher the urethane content, the stronger the dielectric ink becomes after curing.

However, it has been found that increasing the urethane content of the dielectric ink reduces the operating capacitance of the overall electroluminescent structure, thus, for example, reducing the brightness of the luminaire in which the electroluminescent structure is deployed. When the urethane content is selected as an additive to the dielectric layer 110, it is necessary to balance the stiffness and strength requirements with the electroluminescent ability of the structure.

Referring back to Figures 1 and 2 again, the back electrode layer 112 is printed on the dielectric layer 110. The back electrode layer 112 initially contains a one-piece vinyl carrier doping a component to render the suspension electrically conductive. In a preferred embodiment, the dopant of the back electrode layer 112 is silver in particulate form. However, it should be understood that the dopant of the back electrode layer 112 can be any of a variety of conductive materials including, but not limited to, gold, zinc, aluminum, graphite, and copper, or combinations thereof. Experiments have shown that a proprietary mixture containing silver/graphite is suspended in an electronic grade vinyl ink (available from Grace Chemical Company, part number M4200 and M3001-1RS, respectively) suitable for use as the back electrode layer 112. In addition, a suitable pre-mixed silver ink in the form of a vinyl gel is available from Acheson under the trade name EL010. Studies have further shown that useful results can be obtained for layers of about 8 to 12 microns. This layer can be deposited to such a thickness using standard screen printing techniques.

Although it is theoretically possible to add a catalyst to the post electrode ink to convert the carrier from a vinyl to a urethane, it has been found that the use of such a catalyst is practically not feasible. The catalyst was found to be easily overreacted with the back electrode dopant of the ink. Rapid crosslinking allows the ink to become useless within minutes of adding the catalyst.

Referring again to Figures 1 and 2, the second encapsulation layer 114 is then printed onto the back electrode layer 112. It can be seen from Figures 1 and 2 that the preferred printing of the EL system layers 106-112 maintains the border 105 blank. The second encapsulation layer 114 is thus printed and bonded to the first encapsulation layer 104 surrounding the boundary 105, thereby (1) sealing the EL system in the package and thus electrically isolating the EL system, and (2) crosslinking the second encapsulation layer 114. The end of the matured urethane layer of the EL system 106-112 and (3) render the entire laminate substantially water repellent. The second encapsulation layer 114 is also preferably made of the same material of the first encapsulation layer 104. Further as before, the second encapsulation layer 114 can also be deployed into a series of intermediate layers to achieve a predetermined thickness.

As previously mentioned, the laminate comprising the first encapsulation layer 104, the urethane layer on the EL systems 106-112, and the second encapsulation layer 114 now provides a one-piece urethane structure. The catalyst is added to the EL system layer 106-110 originally deployed in the form of a vinyl resin gel which, upon aging, converts the EL system layer 106-110 to the urethane form. The converted urethane EL system layer is bonded and crosslinked to the first and second encapsulation layers 104 and 114, and the encapsulation layers 104 and 114 are deployed in the form of a native urethane. As a result, the resulting urethane laminate has a strong quality and a film-like property as described in the application No. 09/173,404.

The last layer (top layer) shown in Figures 1 and 2 is the adhesive layer 116 as needed. As already mentioned above, one application of the elastomeric EL lamp of the present invention is applied as a transfer to the substrate. In such cases, the transfer can be fixed using a thermal adhesive, but other fastening systems such as contact adhesives can also be used. The advantage of the thermal adhesive is that it can be printed using the same method of the other layers of the layer, and then the transfer storage is prepared as a stock preparation to be fixed to the substrate using a simple hot pressing technique. In this case, as shown in FIGS. 1 and 2, the adhesive layer 116 is printed on the second encapsulation layer 114.

Of course, in other applications of the invention, where the elastomeric EL lamp is a self-contained component of another article, the adhesive layer 116 may not be used as desired.

Yet another feature of Figures 1 and 2 is the pair of rear contact windows 118A and B. It is apparent that in order for the power to energize the EL systems 106-112, the rear contact window 118 is required to reach the back electrode layer 112 through the adhesive layer 116 and the second encapsulation layer 114. Similarly, another window is required to reach the front bus bar 107 through the adhesive layer 116, the second encapsulation layer 114, the back electrode layer 112, the dielectric layer 110, and the luminescent layer 108. This additional window is not shown in Fig. 1, and is deleted in Fig. 1 for clarity, but can be seen in Fig. 2, the contact window 118 extends through all of the layers to the front busbar 107, thus contributing to power supply.

Fig. 3 illustrates the entire assembly as described above substantially when ready to be removed by the transfer release paper 102 after completion. The film-shaped EL lamp 300 (including the respective layers and components 104-116 as shown in Figs. 1 and 2) is peeled off from the transfer release paper 102 to be fixed to the substrate. Rear and front contact windows 118A and 118B are also shown.

It is to be understood (but not shown) that the present invention provides a more economical process for comparing conventional EL lamp manufacturing methods when a large number of identically designed lamps are required. The screen printing technique allows a plurality of EL lamps 300 to be simultaneously formed on a large transfer paper 102. The location of the lamp 300 can be aligned to a single piece of release ester 102 and then simultaneously stamped using a large punch. The individual luminaires 300 are then stored for subsequent use.

As previously described in accordance with the present invention, the appearance of the elastomeric EL lamp 300 in natural light can be designed using dyeing or other techniques and prepared in a selected intermediate layer of the first encapsulation layer 104. According to this technique, FIG. 3 also illustrates that the first portion of the stamp 301 is exposed when the elastomeric EL lamp 300 is torn. The preferred preparation of the stamp 301 is described in detail later.

However, two alternative means of providing power to the elastomeric EL lamp of the present invention are discussed further below. Referring to Figure 4, it can be seen that the elastomeric EL lamp 300 is facing up and is rolled back to expose the rear and front contact windows 118A and 118B. The power is transmitted by the remote power source via the flexible bus bar 401, which is known in the art as a silver circuit printed on the polyester. Additionally, the flexible bus bar 401 can include a conductor (eg, silver) printed on the polyurethane strip. The flexible bus bar 401 terminates in the connector 402. The size, shape and configuration of the flexible bus bar are pre-determined to match the rear and front contact windows 118A and 118B. Connector 402 includes two contact points 403 each of which is received by rear and front contact windows 118A and 118B. Contact point 403 provides the required power to the EL system inside elastomeric EL lamp 300 by mechanical pressure.

In a preferred embodiment, the contact point 403 includes a conductive silicone contact pad that connects the terminals of the flexible bus bar 401 to the electrical contacts within the rear and front contact windows 118A and 118B. This configuration is particularly advantageous when the elastomeric EL lamp 300 is fixed to the substrate by a thermal adhesive. The transfer to the substrate is fixed using a hot press to create electrical contact between the mechanical pressure enhancing silicone contact pads on the contact points 403 and the electrical contact surfaces within the contact windows 118A and 118B. The electrical contact can be further increased between the contact surfaces by the application of a bismuth adhesive. Silicone contact pads are referred to as "conductive silicone" by Chromerics manufacturers. A kind of adhesive is a beautiful Cui 1030.

A particular advantage of using a silicone contact pad is that the silicone absorbs the relative shear displacement of the elastomeric EL lamp 300 and connector 402. For example, compare epoxy resin mechanical joints. The adhesion between the transfer lamp 300 and the connector 402 is extremely strong and relatively rigid and inflexible, so that the relative shear displacement between the transfer lamp 300 and the connector 402 will be directly transferred to either of the two components. Or both. One or the other of the final epoxy cross-linking interfaces (epoxy/transfer lamp 300 or epoxy/connector 402) can be subtracted.

Conversely, the elasticity of the silicone contact pad allows the disposed silicone interface to absorb relative shear displacement without causing degradation of the gasket or electromechanical joint. As a result, severe shear stress may occur due to electrical contact points, thus minimizing the chance of premature power failure of the elastomeric EL lamp 300.

Another alternative means of providing power to the transfer EL lamp of the present invention is shown in Figure 5. In this example, when the current bus bar 107 and the rear electrode layer 112 are printed (as described above with reference to Fig. 1), the elongated portions are also printed beyond the boundary of the elastomer EL lamp 300 to be printed on the tail print bus bar 501. The tail print bus bar 501 passes over the substrate such as a "tail" of polyurethane exposed by the first or second encapsulation layer 104 or 114. In addition, it is to be understood that the conductors of the tail print busbar 501 can be sealed inside the tail extensions of the first and second encapsulation layers 104 and 114, if desired. The power is then connected from the distal end of the transfer EL lamp 300 using the tail print bus 501.

It should be noted that in the preferred embodiment, the power supply uses a very low profile battery/inverter printed circuit. For example, germanium wafer based inverters provide very low profile and size. These power supply components are easily concealed and the elastomeric EL lamp article used in the present invention is safe and unobstructed. For example, for clothing, power supply components can be effectively hidden in special pockets. The pocket can be closed for safety (eg fake padding). Industry standard power supplies such as lithium 6 volt batteries also provide flexibility and ductility to allow the battery to be folded and bent with clothing. It is further known that the flexible bus bar 401 is shown in FIG. 4, or the tail printed bus bar 501 is easily sealed as shown in FIG. 5 to provide complete electrical isolation and then conveniently concealed inside the article structure.

Turning now to printing techniques, the present invention also discloses improvements in EL lamp printing techniques that have evolved EL lamps (including elastomeric EL lamps) whose passive natural light appearance is designed to complement the active electroluminescent appearance. Such complementation includes the design of the passive natural light appearance of the EL lamp being substantially equal to the electroluminescent appearance, so that at least in terms of image and hue, the EL luminaire has the same appearance whether illuminated or unlit. In addition, the luminaire can be designed to display a constant image, but when it is illuminated, its portion can change the hue when it is illuminated. In addition, the appearance of the EL lamp can also be designed to change the appearance when lighting.

Printing techniques that can combine such effects include (1) altering the type of phosphor used (e.g., luminescent color) used in the electroluminescent layer 108, and (2) selecting a dye by which the color layer is printed on the electroluminescent layer 108, and (3) Use point screening printing technology to achieve a gradual change in the appearance color tone when the EL lamp is lit and not lit.

Figure 6 shows these techniques. The cut-away portion 601 of the elastomeric EL lamp 300 displays the electroluminescent layer 108. At the cut-out portion 601, three separate electroluminescent segments 602B, 602W, and 602G are printed, each segment being printed using a phosphorous-containing electroluminescent material that emits different colored lights (blue, white, and green). It is necessary to understand that the screen printing technology known in the art can separately print three sections 602B, 602W and 602G. Sections that emit different colored lights in this manner can be printed and, if desired, combined with unlit segments (i.e., unprinted portions of electroluminescent material) and depicted when electroluminescent layer 108 is electrically energized Any design, stamp or information to display.

The appearance of the electroluminescent layer 108 when electrically excited is further modified via selective coloration (preferably by dyeing) followed by insertion of the layers in front of the electroluminescent layer 108 and the EL lamp. Such selective coloring can be further controlled via printing a colored layer only over selected segments above the electroluminescent layer 108.

Referring again to FIG. 6, the elastomeric EL lamp 300 has a first encapsulation layer 104 disposed over the electroluminescent layer 108. As described above with reference to FIGS. 1 and 2, the first encapsulation layer 104 can be printed by laying a plurality of intermediate layers. To a predetermined thickness. One or more of the layers include an encapsulating layer material that is dyed to a predetermined color and printed, such that the coloring can be complemented by the desired active light below. As a result, a predetermined overall combination effect is produced when the EL lamps are alternately illuminated and not illuminated.

For example, in Fig. 6, it is assumed that section 603B is blue for section 603X, section 603R is reddish, and section 603P is grayed out. The natural light appearance of the elastomeric EL lamp 300 has substantially a reddish purple stripe design 605 and a blue border 606. The red segment 603R and the purple segment 603P may modify the white tint of the lower segment 602W, and the uncolored segment 603X will exhibit an unmodified hue hue for the lower segment 602B. And the blue segment 603B will modify the light green/serge shade of the lower segment 602G to produce a slightly dark blue appearance. It is to be understood that the blue tint of section 603B is further selected so that when the green color of the lower section 602G is combined, the natural light appearance also becomes substantially the same blue.

However, when the elastomer EL lamp 300 is electrically excited, the segments 603R, 603P, and 603X maintain red, purple, and blue, respectively, and the intense green phosphor light from the lower portion of the segment 603B is modified by the blue of the segment 603B to turn blue-green. . This produces an effect in which part of the image is designed to have the same appearance regardless of whether the elastomeric EL lamp 300 is lit, and the other portion of the image changes its appearance upon electrical excitation.

Combining the various colored segments described above by printing various colored phosphor segments will have almost unlimited design variations when the illuminated and unlit appearance of the luminaires are correlated. It is important to understand that the design flexibility and range of such lit/unlit appearances is not possible with conventional EL manufacturing techniques because traditional EL manufacturing techniques are difficult to accurately print "segments" of various colors or within one-piece thickness. Out of the middle layer.

It is further emphasized that in the aforementioned coloring technique, it is preferred to mix the fluorescent colored dye to the coloring material instead of using a coating or other colored layer. This dyeing helps to reflect the natural light and the active EL light to visually measure the perceived hue. As the industry knows, color mixing can also be carried out by "trying the wrong" or by computerizing colors such as the colors of more traditional mixed paints.

The transition section 620 between sections 603B and 603X is further described with reference to FIG. The intent transition section 620 represents a darker shade of section 603B (when the elastomeric EL lamp 300 is electrically energized) progressively transitions to a lighter blue of section 603X.

The standard way of printing is to use "printing". Such "printing" technology can be carried out by screen printing. It is known that "spot printing" is to merge the boundaries of two adjacent printing sections to form a name transition section. The points from the adjacent segments are extended into the transition segment, and the dot spacing is increased as the point extends into the transition segment. Thus, when the dot patterns of the transition sections are overlapped or overlapped, the effect is obtained by progressively changing one adjacent section through the transition section to the next section.

It is to be understood that such effects are readily achieved by the present invention. Referring again to Figure 6, the colored layer providing a particular hue in section 603B can be printed to allow the point to extend into the transition section 620, as the point expands into the transition section 620 as the point size decreases and the spacing increases. A dyed layer that provides a particular hue in section 603X can then be printed on top of it, with the dots extending into the transition section 620 in a reciprocating manner. The radial light obtained by both the natural light and the active light is gradually transitioned from a hue to a next hue.

Having described the invention and its advantages, it is to be understood that various changes, substitutions and changes may be made herein without departing from the spirit and scope of the invention.

Main component symbol description

102. . . Transfer release paper

104. . . Encapsulation layer

105. . . boundary

106. . . Translucent electrode layer

107. . . Front bus

108. . . Luminous layer

110. . . Dielectric layer

112. . . Back electrode layer

114. . . Encapsulation layer

116. . . Adhesive layer

118A. . . Rear contact window

118B. . . Front contact window

300. . . Membrane electroluminescent lamp

401. . . Flexible bus

402. . . Connector

403. . . Contact point

501. . . Tail printing bus

601. . . Resection

602B, G, W. . . Electroluminescent section

603B, P, R, X. . . Section

620. . . Transition section