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    • 专利摘要:
    PROCESS TO PRODUCE A CONFORMED ELECTROLUMINESCENT SYSTEM. A process for producing a shaped electroluminescent system. An electrically conductive base backplane film layer (16) is applied over a substrate (12). A dielectric film layer (18) is applied over the backplane film layer (16), then a phosphor film layer (20) is applied over the dielectric film layer (18). An electrode film layer (22) is applied over the phosphor film layer (20) using a substantially transparent, electrically conductive material. An electrically conducting busbar (24) can be applied over the electrode film layer (22). Preferably, the backplane film layer (16), the dielectric film layer (18), the phosphor film layer (20), the electrode film layer (22) and the busbar (24) are of water-based and are applied by spray shaped coating.
    公开号:BR112014016393B1
    申请号:R112014016393-6
    申请日:2013-01-03
    公开日:2021-07-06
    发明作者:Andrew Zsinko；Shawn J. Mastrian
    申请人:Darkside Scientific, Inc；
    IPC主号:
    专利说明:

    [0001] This application claims priority from US patent application 13/677,864, filed November 15, 2012 which is a continuation of US patent application 13/624,910, filed September 22, 2012, which claims priority US Patent Application Provisional Application 61/582,581, filed January 3, 2012. The entire contents of each of these applications are hereby incorporated by reference. TECHNICAL FIELD
    [0002] The present invention relates to a system for the production of electroluminescent devices with a lower backplan electrode layer and an upper electrode layer, the lower and upper electrode layers being connected to an electrical conduction circuit. One or more functional layers are disposed between the upper and lower electrode layers so as to form at least one electroluminescent area. FUNDAMENTALS OF THE INVENTION
    [0003] Since the 1980s, electroluminescent (EL) technology has come into wide use in display devices where its relatively low power consumption, relative brightness and ability to be formed into relatively thin film configurations have shown that diodes are preferable. light emitting (LEDs) and incandescent technologies for many applications.
    [0004] Commercially manufactured devices have traditionally been produced using blade coating and printing processes such as screen printing or, more recently, inkjet printing. For applications requiring relatively flat EL devices, these processes have worked reasonably well, as they lend themselves to high-volume production with relatively efficient and reliable quality control.
    [0005] However, traditional processes are inherently self-limiting for applications where it is desirable for an EL device to a surface having complex topologies such as convex, concave and curved surfaces. Partial solutions have been developed in which a relatively thin film EL "decal" is applied to a surface, with the decal subsequently being encapsulated within a polymer matrix. While moderately successful, this type of solution has several inherent weaknesses. First, while decals may be acceptable conforming to slight concave/convex topologies, they are unable to conform to tight radius curves without stretching or wrinkling. Furthermore, the decal itself does not form either a chemical or mechanical bond with an encapsulation polymer, essentially remaining a foreign object incorporated within the encapsulation matrix. These deficiencies present difficulties in product manufacturing and life cycle, as EL-embedded decal lamps applied to complex topologies are difficult to produce and are susceptible to delamination due to mechanical and thermal stresses and long-term exposure to ultraviolet (UV) radiation ). There continues to be a need for a way to produce an EL lamp that is compatible with items having a surface incorporating complex topologies. SUMMARY OF THE INVENTION
    [0006] A process is disclosed according to an embodiment of the present invention wherein an EL device is "painted" onto a surface or "substrate" of a destination point to which the EL device is to be applied. The present invention is applied to the substrate of a series of layers, each of which performs a specific function as part of the process.
    [0007] An object of the present invention is a process for the production of a shaped electroluminescent system. The process includes the step of selecting a substrate. The base backplane film layer is applied over the selection substrate using a water-based, electrically conductive backplane material. A dielectric film layer is applied over the backplane film layer using a water-based dielectric material. A phosphor film layer is applied over the dielectric film layer using an aqueous-based phosphor material, the phosphor film layer being excited by a source of ultraviolet radiation during application. The ultraviolet radiation source provides visual cues while the phosphor film layer is being applied, as well as the application of the phosphor film layer is adjusted in response to visual signals to apply a generally uniform distribution of the phosphor material over the layer. of dielectric film. An electrode film layer is applied over the phosphor film layer using a substantially transparent, water-based, electrically conductive electrode material. The backplane film layer, dielectric film layer, phosphor film layer, and electrode film layer are each preferably applied by insulating spray coating. The phosphor film layer is excitable by an electric field established through the phosphor film layer upon application of an electrical charge between the backplane film layer and the electrode film layer such that the phosphor film layer emits electroluminescent light. BRIEF DESCRIPTION OF THE DRAWINGS
    [0008] Other features of embodiments of the invention will be apparent to those skilled in the art to which the embodiments pertain from reading the specification and claims with reference to the accompanying drawings, in which: Fig. 1 is a diagram schematic layer of an EL lamp according to an embodiment of the present invention; Fig. 2 is a flow diagram of a process for producing electroluminescent lamps according to an embodiment of the present invention; Fig. 3 is a schematic diagram of an EL lamp layer showing routing of conductive elements in accordance with an embodiment of the present invention; Fig. 4 is a schematic diagram of an EL lamp layer showing routing of conductive elements in accordance with another embodiment of the present invention; Fig. 5 is a flow diagram of a process for applying a phosphor layer according to an embodiment of the present invention; Fig. 6 is a schematic diagram of an EL lamp layer having a color coating according to an embodiment of the present invention; Fig. 7 is a schematic layer diagram showing light being reflected by the color coating of Figure 6 and imparting color effect to the light; Fig. 8 is a schematic diagram showing the layer of light passing through the color coating of Fig. 6, providing an enhanced color effect of reflected light; Fig. 9 is a schematic layer diagram of a multilayer EL lamp with upper layer wires according to an embodiment of the present invention; Fig. 10 is a schematic layer diagram of a multilayer EL lamp with lower layer wires according to another embodiment of the present invention; Fig. 11 is a schematic layer diagram of a multilayer EL lamp with double layer wires according to yet another embodiment of the present invention; Fig. 12 is a schematic diagram of a multilayer layer with dual layer EL Lamp wires according to yet another embodiment of the present invention; and Fig. 13 is a schematic layer diagram of an EL lamp having a transparent substrate in accordance with yet another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION
    [0009] In the description that follows, like reference numerals are used to refer to like elements and structures in the various Figures.
    [0010] The general arrangement of a shaped EL lamp 10 is shown in Fig. 1 according to an embodiment of the present invention. The EL lamp 10 comprises a substrate 12, a primary layer 14, an electrically conductive backplane electrode layer 16, a dielectric layer 18, a phosphor layer 20, a substantially transparent electrically conductive upper electrode 22, a bus bar 24 and an optional encapsulation layer 26. Substrate 12 can be a selected surface of any suitable target item onto which the EL lamp 10 is to be applied. Substrate 12 can be conductive or non-conductive and can have any desired combination of convex, concave and curved surfaces. In some embodiments of the present invention, substrate 12 is a transparent material such as, without limitation, glass or plastic.
    [0011] Primer layer 14 is a non-conductive coating film applied to substrate 12. Primer layer 14 serves to electrically insulate substrate 12 from subsequent conductive and semiconductor layers, discussed further below. Primer layer 14 also preferably promotes adhesion between substrate 12 and subsequent layers.
    [0012] The conductive backplane 16 is a film coating layer which is preferably masked over primer layer 14 to form a background electrode of the EL lamp 10. The conductive backplane 16 is preferably a sprayable conductive material. and can form the outline of the EL "field" of the finished EL 10 lamp. The material selected for backplane 16 can be adapted as desired to meet varying environmental and application requirements. In one embodiment backplane 16 is made using a highly conductive, generally opaque material. Examples of such materials include, without limitation, a silver alcohol/latex-based filler solution, such as SILVASPRAY™ available from Caswell, Inc. of Lyons New York, and a water-based latex, copper solution loaded, such as "Caswell Copper" copper conductive paint, also available from Caswell, Inc.
    [0013] In one embodiment, a predetermined amount of silver flakes may be mixed with the conductive copper paint. Empirical tests show that the addition of flake silver significantly improves the performance of the conductive copper paint without adversely affecting its relatively environmentally friendly characteristics.
    [0014] As an alternative to Caswell SILVASPRAY™ or Caswell copper, silver flakes can be mixed with a solution of an aqueous solution based on styrene acrylic copolymer (discussed later) and ammonia to encapsulate the silver for application to a prepared surface (ie substrate) as a backplane material 16.
    [0015] The conductive backplane 16 may also be a metallic coating, in which a suitable conductive metallic material is applied to a non-conductive substrate 12, using any process suitable for the metal select plating. Example types of plating include, without limitation, electroless plating, vacuum plating, vapor deposition, and sputtering. Preferably, the resulting electrically conductive backplane 16 has a relatively low resistance to minimize voltage gradients across the surface of the backplane to allow proper functioning of the electroluminescent system (i.e., sufficient lamp brightness and brightness uniformity). In some embodiments the resistance of a plated backplane 16 is preferably less than about one ohm per square centimeter of surface area.
    [0016] The conductive backplane 16 may also be an electrically conductive, generally clear layer, such as, without limitation, "CLEVIOS ™ S V3" and or "CLEVIOS ™ S V4" conductive polymers, available from Heraeus GmbH Clevios de Leverkusen , Germany. This configuration may be preferred for use with target articles generally having transparent substrates, such as glass and plastic, and for embodiments where a full application of thinner layers for EL Lamp 10 is desired.
    [0017] The dielectric layer 18 is an electrically non-conductive film coating layer comprising a material (typically barium titanate - BaTiO3) that has high dielectric constant properties encapsulated within an insulating polymer matrix having relatively high permittivity characteristics (ie, an index of the ability of a given material to transmit an electromagnetic field). In one embodiment of the present invention the dielectric layer 18 comprises about 2:1 of copolymer solution and dilute ammonium hydroxide. To this solution an amount of BaTi0 3 , which has been pre-wetted in ammonium hydroxide, is added to form a supersaturated suspension. In various embodiments of the present invention, dielectric layer 18 can comprise at least one of a titanate, an oxide, a niobate, an aluminate, a tantalate, and a zirconate material, among others.
    [0018] The dielectric layer 18 serves two functions. First, dielectric layer 18 provides an insulating barrier between backplane layer 16 and superimposed semiconductor phosphor 20, top electrode 22 and 24-layer busbar. In addition, because of the unique electromagnetic polarization characteristics of dielectric materials, dielectric layer 18 serves to improve the performance of the electromagnetic field generated between backplane 16 and higher of electrode 22 layers when an AC 28 signal is applied between the backplane and the electrode start, the AC signal generating an electric field or electrical charge between the backplane and the top of the electrode. Furthermore, despite being an effective electrical insulator, the high dielectric quality of the BaTi0 3 and the high permittivity of the polymer matrix are highly permeable to the electrostatic field generated between 16 and electrode top backplane 22
    [0019] Furthermore, in multiple layer applications of EL lamps a dielectric layer 18 that has photorefractive qualities can be selected, in which the refractive index of the dielectric layer is affected by an electric field applied to the backplane electrode 16 and 22 through a CA 28 signal (Fig. 1). These photorefractive qualities of the dielectric layer material 18 can be used to facilitate the propagation of light through the overlapping layers of the EL lamp. A non-limiting exemplary material having photorefractive properties is BaTiO3 .
    [0020] The phosphor layer 20 is a semiconductor film coating layer composed of a material (typically doped with zinc metal sulfide (ZnS)) encapsulated within a highly electrostatically permeable polymer matrix. When excited by the presence of an alternating electrostatic field generated by the AC 28 signal, the doped ZnS absorbs energy from the field, which in turn re-emits as a visible light photon upon returning to its ground state. Phosphor layer 20 serves two functions. First, while metal-doped phosphorus Zinc Sulfide is technically classified as a semiconductor, when encapsulated within the copolymer matrix, it more effectively provides an additional barrier of insulation between the layer 16 backplane and the overlapped upper electrode 22 and busbar. 24 layers. Furthermore, once excited by the presence of an alternate electromagnetic field, the phosphor layer 20 emits visible light.
    [0021] In an embodiment of the present invention the phosphorus layer 20 comprises about 2:1 copolymer solution and dilute ammonium hydroxide. To this solution, an amount of zinc based sulfide phosphors doped with metals doped with at least one of copper, manganese and silver (ie, the ZnS: Cu, Mn, Ag, etc.) pre-wetted in a hydroxide solution of dilute ammonium is added to form a supersaturated suspension.
    [0022] Preferably, an aqueous-based styrene acrylic copolymer solution (hereinafter "copolymer") is used as an encapsulating matrix for both the dielectric layer 18 and the phosphor layer 20. This material is suitable for the proximity-end and long-term contact without adverse impact on organisms or the environment. An example of a copolymer is DURAPLUS™ Polymer Matrix, available from the Dow Chemical Company of Midland, Michigan. A significant advantage of the copolymer is that it provides a chemically benign and versatile binding mechanism for a variety of under- and top-coating options on a selected substrate. 12. Ammonium hydroxide can be used as a diluent/drying agent for the copolymer.
    [0023] During the production of EL lamp 10, after the volatile components of the copolymer solution of dielectric layer 18 and phosphor layer 20 have been eliminated (typically by evaporation) during a curing process, the resulting coatings are largely chemically inert. As such, dielectric layer 18 and phosphor layer 20 coatings do not readily react chemically with under-or over-laying layers and, as a result, encapsulate and protect homogeneous phosphor 20 and dielectric particle layer distributions.
    [0024] Chemically, during a curing process, the open ends of a copolymer of dielectric layer 18 and long-chain phosphorus layer 20 are exposed. This provides a ready mechanism for creating a strong mechanical bond between the chemically dissimilar layers, as the exposed polymer chain ends up essentially functioning as a "hook" analogous to the hook portion of a hook and loop fastener. These hooks provide a relatively porous surface topology that easily accepts infiltration through the application of a second long chain polymer solution. As the secondary layers cure, the ends of the polymer chain and are exposed to essentially "mesh", with the aforementioned exposed copolymer ends to form a strong mechanical bond between adjacent layers.
    [0025] The upper electrode 22 is a film coating layer that is preferably both electrically conductive and generally transparent to light. Top 22 electrode can be from materials such as, without limitation, conductive polymers (PEDOT), carbon nanotubes (CNT), tin antimony oxide (ATO) and indium tin oxide (ITO). A preferred commercial product is CLEVIOS™ conductive, transparent and flexible polymers (available from Heraeus GmbH Clevios of Leverkusen, Germany) diluted in isopropyl alcohol as a thinning/drying agent. CLEVIOS™ conductive polymers exhibit relatively high efficacy and are relatively environmentally benign. Furthermore, CLEVIOS™ conductive polymers are based on a styrene copolymer and therefore provide a ready mechanism for chemical crosslinking/mechanical bonding with the underlying layer of phosphorus 20.
    [0026] Alternative materials can be selected for superior electrode 22 solutions, including those containing Indium Tin Oxide (ITO) and Antimony Tin Oxide (ATO). However, these are less desirable than CLEVIOS™ conductive polymers due to greater environmental concerns.
    [0027] In some embodiments of the present invention, it may be desirable for the backplane electrode layer 16 to be generally transparent. In such cases, any of the materials discussed above for the top of electrode 22 can be used for the backplane electrode layer 16.
    [0028] The efficiency of upper electrode 22 materials is hampered by their divergent operational requirements; that of both being electrically conductive, being also generally transparent to visible light. As the illuminated field area of an EL 10 lamp becomes larger, a decreasing return point is approximated at which the thickness of the upper electrode layer 22 to achieve a sufficiently low resistivity for the necessary voltage distribution across the Top electrode layer becomes optically or inhibiting, on the other hand, the thickness of the top electrode becomes unacceptably electrically inefficient. As a result, it is often desirable to augment the transparent upper electrode layer 22 with an electrical conductor as close to the illuminated field as possible, so as to minimize the thickness of the upper electrode layer for optimal optical characteristics. Bus 24 satisfies this requirement by providing a relatively low impedance strip of conductive material, typically composed of one or more of the materials usable to produce backplane as conductive 16. Bus bar 24 is typically applied to the peripheral edge of the illuminated field.
    [0029] Although the busbar 24 is generally shown as adjacent to the top of the electrode layer 22 in the Figures, in practice the busbar can be applied on top (ie, on top) of the top electrode layer. On the other hand, the upper electrode layer 22 can be applied on top (i.e., on top) of the busbar 24.
    [0030] Once applied, the top electrode 22 and the busbar 24 are susceptible to damage due to scratches or marking. After curing the top of the electrode 22 and the busbar 24, it is preferable to encapsulate the EL lamp 10 with a clear encapsulating film coat layer 26, such as a clear polymer 26 of suitable hardness to protect the EL lamp from damage. The encapsulation of layer 26 is preferably an electrically insulating material applied over the EL Lamp 10 battery, thereby protecting the lamp from external damage. The encapsulation of layer 26 is also preferably generally transparent to the light emitted by lamp 10 of the ELse cell and is preferably chemically compatible with any anticipated topcoat materials for substrate target 12, which provide a mechanism for chemical and/or mechanical fastening with top coat layers. Encapsulation layer 26 can consist of any number of aqueous, enamel or lacquer based products.
    [0031] As noted earlier, current EL products are limited to application on relatively simple topographical surfaces that are flat or nearly flat. This is because silkscreen/inkjet based processes require a flat or nearly flat surface to ensure proper distribution ratios of the required components in the respective layers. Unlike EL print-based production processes, the initiator layer 14, backplane 16, dielectric layer 18, phosphor layer 20, top electrode conductor 22, busbar 24 and an encapsulation layer 26 are preferably formulated to be compatible with and applied by both instruments and methods commonly available and within the reach of the painter's craft. Thus, EL 10 Lamp can be "painted" on 12 substrate as a stackup of insulating coatings comprising primer layer 14, backplane 16, dielectric layer 18, phosphor layer 20, electrode top conductor 22, busbar 24 and encapsulating layer 26. Using select components from the respective layers and application techniques, as disclosed herein, that are compatible with the spray-based material, EL lamps 10 can be applied to a wide variety of materials and/or complex topologies such as any substrate 12 "paintable" surface can be used for the application of an insulating, energy-efficient EL lamp. Therefore, Lamp EL 10 is "shaped" in the sense that it adapts to the shape and geometry of the substrate 12.
    [0032] With reference to Fig. 2 in combination with Fig. 1, a process s100 for producing EL lamps will now be described.
    [0033] In s102 a substrate 12 is selected. Substrate 12 is typically a target item select surface, which can be made from any suitable conductive or non-conductive material, and can have any desired contours and shapes.
    [0034] A coat of primer 14 is applied to substrate 14 at s104. If the desired substrate target product 12 is conductive, i.e., metal, or carbon fiber, or non-conductive, i.e., some form of glass, plastic, fiberglass, or composite material, it is preferable to apply an amount of an initiator Substrate-compatible oxide-based, in a relatively thin layer, to seal the surface, provide electrical insulation between the substrate and the EL 10 lamp, and ensure adhesion of topcoat layers over overlyings. In some circumstances, it may also be desirable to apply a thin layer of a suitable water-based enamel/lacquer/paint, compatible with the desired finish, over the oxide primer layer. "Topcoat" as used herein generally refers to any coating placed over finished on the EL lamp 10, such as a clear coating covering the light and parts of the substrate 12 not covered by the EL lamp. The optional painting step s106 is particularly interesting when the target item comprising substrate 12 is being subjected to prolonged manipulation before a new EL lamp 10 layers are applied. Because of the relative "smoothness" of oxide-based initiators, the exposed surfaces of the initiators can be degraded by frequent handling and the resulting oxide powder can stain the raw surface.
    [0035] For each EL "illuminated field" on a given surface, two electrical connections are provided in SL08 to provide a path for the AC 28 signal (Fig. 1) that excites the phosphor layer 20. There are two basic mechanisms for the installation of these electrical paths, the selection of which is determined by the characteristics of the substrate 12 of the target element. With additional reference to Fig. 3, for non-conductive plastic, fiberglass or composite substrates of 12 target items, it is preferable to provide one or more "carrythrough" conductive elements 30-1, 30-2 for 16 backplane and 24, respectively, bus EL lamp bar 10 via small 32 openings in substrate 12 of the target item and primer layer 14 to provide electrical contact with the overlying backplane and bus. For some forms of substrate 12-item target conductors, the carrythrough technique is also effective, given the inclusion of an insulating layer 34 between the substrate and the signal path. This is both a practice and a safety consideration, as the demand for electrical current placed in the power system unnecessarily on the substrate/target item significantly reduces the energy consumption efficiency of the system as a whole and increases safety by electrically isolating the field. EL lamp 10 from a conductive substrate 12 of the target item and any pathways to a ground state, such as a defect in the target product substrate.
    [0036] When structural or practical considerations (such as maintaining the integrity of a fluid containment vessel) prohibit the use of the aforementioned canythrough technique of Fig. 3 on a substrate 12 of a target article, the signaling paths for EL 10 lamp can be provided by incorporating 30-1 and 30-2 conductive elements into the insulation primer layer 14 and, if necessary, "molding" one end of the panel as shown in Fig. 4. Any of the methods in Figs. 3 and 4 to provide signal access to backplane 16 and bus 24, i.e. "carrythrough" or "molding", are functionally equivalent and can be selected based on specific conditions and requirements imposed by substrate 12 of the target item.
    [0037] The backplane layer 16 is applied in s110. Backplane layer 16, as discussed above, is a pattern that comprises a conductive material and is masked during coating primer 14 . Backplane layer 16 can be applied to any suitable thickness, such as about 0.001 inches, preferably using gravity feed fine aperture type spraying equipment. When so applied, backplane layer 16 is placed in electrical contact with conductive element 30-1 (Figures 3, 4) to provide electrical contact with AC signal 28 and also defines the outline of the illuminated field Lamp EL 10.
    [0038] The dielectric film layer 18 is applied by spraying in step s112. The dielectric supersaturated solution described above is applied through suction and/or the type of supply of pressure spray equipment, under visible light, at a predetermined air pressure, adjusted for variables such as ambient temperature and topology of the substrate target item 12. Dielectric layer 18 is preferably applied at ambient air temperature of about 70 degrees centigrade or higher. The dielectric layer is preferably applied in successive thin layers of solution to ensure an even distribution of the BaTiO3 particles/polymer solution and prevent excessive build-up that could overcome the surface tension of the solution, which in turn can create a "run" or "tilt" within the applied layers. Excessive build-up of material that results in running or tilting of the applied layers leads to an uneven aggregation of the encapsulated particles (referred to as "sand duning") which has a direct negative effect on the appearance of the final product. Therefore, it is often desirable to increase the initial air cure of successive applied layers by applying improved infrared radiation from sources, such as direct sunlight and enhanced infrared lamps between layers, for a period of time. determinable depending on ambient temperature and humidity conditions.
    [0039] The phosphor layer 20 is applied at s114. The supersaturated phosphorus solution discussed above is applied using suction and/or spray equipment pressure supply type, at a predetermined air pressure, adjusted for variables such as ambient temperature and target substrate 12 topology item. The phosphor layer 20 is preferably applied in proximity (e.g. under) an ultraviolet radiation source, such as a long wave ultraviolet light (e.g. UV "A" or "black light" ultraviolet light) to enhance Visible indicators or clues to the operator during application to ensure relatively even particle distribution. The phosphor layer 20 is preferably applied at an ambient air temperature of about 70 degrees centigrade or higher. The phosphorus layer 20 is preferably applied in successive thin layers of solution to ensure an even distribution of the ZnS-particulate/polymer solution, and to prevent excessive build-up that could overcome the surface tension of the solution, in turn creating a " run" or "tilt "within the applied phosphor layers. As dielectric layer 18, excessive accumulation of material that results in "sliding" or tipping "of the applied layers can lead to uneven pooling of the encapsulate into particles (ie, "sand duning") which has a direct detrimental effect on the appearance of the the final product. Therefore, it is preferable to increase the initial air curing of successive applied layers by applying more infrared radiation through sources such as direct sunlight and improved infrared lamps between layers, for a period of time. determinable, depending on Environmental conditions such as temperature and humidity.
    [0040] More details on the application of the phosphor layer 20 are shown in Fig. 5. The above-discussed supersaturated phosphorus solution is applied using suction and/or spray type air pressure supply equipment at a predetermined pressure , adjusted for variables such as ambient temperature and topology of substrate 12 of the target element. Phosphor layer 20 is preferably applied under the aforementioned ultraviolet radiation source to improve visible indicators or clues to the operator during application to ensure relatively uniform particle distribution.
    [0041] In s114-1, prior to application of the phosphor layer 20 an operator preferably provides an ultraviolet radiation source such that the ultraviolet radiation source will generally uniformly illuminate a target spot to be painted. The ultraviolet radiation source is preferably located in a room or other area that is darkened or otherwise substantially devoid of other light sources, so that the ultraviolet radiation source is the main source of light on the object to be painted.
    [0042] Phosphor layer 20 is applied to substrate 12 of target item s114-2. When applying the phosphor layer, the operator notices that it will glow intensely under the ultraviolet radiation source. This provides a visual indication for coating quality, whereas under typical ambient white light the operator is not able to distinguish phosphor layer 20 from dielectric layer 18, because the two layers will visually mix.
    [0043] In s114-3, as the operator preferably applies a phosphor film layer 20 comprising one or more relatively thin phosphor layers under the ultraviolet radiation source, the operator will notice that the phosphor layer coating becomes if more uniform and therefore will know where to apply more or less phosphor layer coating in order to ensure the finished phosphor layer is as uniform as desired. The phosphor film layer of 20 to be applied is excited by the aforementioned ultraviolet radiation source during application, the ultraviolet radiation source, thus providing the operator with visual cues while the phosphor film layer is being applied. At s1 14-4 the operator adjusts the application of the phosphor film layer 20 in response to visual signals to apply a generally uniform distribution of the phosphor material over the dielectric film layer 18. phosphor of about 0.001 inches or less is preferred. The insulating coating process is completed at sl 14-5 once the phosphor film layer 20 has reached the desired thickness and uniformity.
    [0044] Since components of the phosphor 20 and dielectric 18 layer of the present invention are chemically identical, in addition to inert particulate components, they are functionally applied in a contiguous process that chemically forms a single heterogeneous, chemically cross-linked layer only distinguished by particulate encapsulated inert.
    [0045] With continued reference to Fig. 2, once a desired thickness and distribution of phosphor 20 and dielectric 18 layers have been deposited at steps s112, s114, respectively, the resulting coating is allowed to cure at s116 for a period of time determinable, sufficient to evacuate the remaining water content of the dielectric and phosphorus layers by means of evaporation, and also allow a mechanical bond between the applied dielectric/phosphorus and backplane 16 to form layers. This time period varies depending on environmental factors such as temperature and humidity. The process can optionally be accelerated by means of infrared heat sources described above for s112 and s114.
    [0046] The busbar 24 is applied in s118. Typically, the bus 24 is applied using a fine spray or opening of suitable gravity feed spray equipment such that the bus bar preferably forms an electrically conductive path, which generally follows the circumference of a given EL illuminated field to provide an effective current source to, and electrical contact with, the transparent top electrode layer 22 and define the outer edge of the desired pattern of the EL field.
    [0047] For some EL lamps the surface area of the illuminated field is large enough that a bus bar 24 applied to the periphery of the illuminated field does not provide an adequate voltage distribution for the lamp from portions further away from the busbar, such as as the center of the large rectangular lamp. Likewise, some May 12 substrates have an irregular geometry, resulting in areas of the illuminated field that are away from bus 24. In such situations, bus bar 24 may include one or more "fingers" of communicating bus bar material electric with the bus bar and extends outward from the bus bar to the far portion(s) of the EL lamp.
    [0048] Likewise, a suitable grid pattern may be in electrical communication with the bus bar 24 and extends outward from the bus bar to the far portion(s) of the EL lamp.
    [0049] The upper electrode 22 is applied over the phosphor layer 20 and bar bar 24 in s120 using an air brush or suitable fine aperture gravity feed spray equipment such that the upper electrode forms a conductive path that bridges the busbar on the circumference of the EL field to provide a generally optically transparent conductive layer over the entire surface area of the EL field. Preferably, electrode top 22 is applied with an electrical operative signal 28 applied to electrode top and backplane 16 to visually monitor illumination of phosphor layer 20 during electrode top application. This allows the operator to determine if the top coating of electrode 22 has achieved sufficient thickness and efficiency to allow the light to illuminate EL in the desired mode. Each coating is preferably allowed to define the scope of application of enhanced infrared radiation between each coating to allow for air evaporation of aqueous/alcohol components from the solution. The number of layers required is determined by the uniformity of material distribution, as well as the specific local conductivity as determined by the physical distance between all bus bars 24 gaps.
    [0050] Layer 26 encapsulation is applied in s122. Preferably, the encapsulating layer 26 is applied so as to completely cover the EL lamp stack 10, thus protecting the EL lamp from damage.
    [0051] In some embodiments of the present invention the EL 10 lamp may include additional features to manipulate the apparent color emitted by the lamp. In such an embodiment a coating 36 of color-SL24 pigment (Fig. 2) is applied on EL Lamp 10, as shown in Fig. 6.
    [0052] In other embodiments the reflected light and/or the emitted light can be used to manipulate the apparent color emitted by the 10 EL lamp. Under environmental conditions, the apparent color of a surface is determined by the absorption and reflection of various frequencies of light. Therefore, it is possible to effect an alteration or change of apparent color by the selective use of colored matches, together with shaded overcoats. Fig. 7 shows an EL lamp with reflected light modifying the color of the EL lamp 10, while Fig. 8 shows the emitted light modifying the apparent color of the light emitted by the EL lamp.
    [0053] Both BaTiO3and ZnS particulate components of dielectric layer 18 and phosphor layer 20, respectively, each exhibit significant properties of optical translucency to light at visible wavelengths. As a result, it is possible to directly overlay layers of Lamp EL 10, separated by a layer of an optically generally transparent encapsulant 38, to take advantage of these properties. By alternatively or coincidentally energizing the respective layers, substantial modification of apparent color is possible. Combining this technique with the previously described dyeing and reflective/emissive top coating procedures presents a wide range of possibilities for customizing the base of the EL 10 lamp. Fig. 9 shows a multilayer configuration EL lamp 50 with top layer wiring, Fig. 10 shows a multilayer configuration EL 60 Lamp with lower layer wiring, and Fig. 11 shows a multilayer configuration EL 70 Lamp with double layer wiring. Lamp ELs of 50, 60, 70 are otherwise similar to lamp EL 10 in materials and construction.
    [0054] An EL 80 lamp is shown in Fig. 12 according to yet another embodiment of the present invention. EL lamp 80 includes a substrate 12, which preferably is made of a generally transparent material, such as glass or plastic. In the EL 80 lamp stackup a first 24-1 bus is applied to substrate 12. A primer layer of generally transparent electrode film 22-1 is applied after the first 24-1 bus bar. -1 is applied after the electrode 22-1 film primer layer. Dielectric layer 18 is applied after phosphor primer layer 20-1. A second layer of phosphorus 20-2 is applied on dielectric layer 18. A second layer of transparent film generally electrode 22-2 is applied on second layer of phosphorus 20-2. Finally, a clear encapsulating coating 26 is optionally applied on the second layer of electrode film 22-2. EL 80 lamp is otherwise similar to EL 10 lamp in materials and construction.
    [0055] In EL 80 Lamp operation, the AC 28 signal is applied to busbars 24-1, 24-2 as shown in Fig. 12. The AC signal is electrically conducted from buses 24-1, 24-2 Electrode 22-1, 22-2, respectively, generating an AC field through 20-1 and 20-2 phosphor layers. Phosphor layers 20-1 and 20-2 are excited with the AC field, causing the phosphor layers to emit light. Light emitted by phosphor layer 20-1 is directed towards and though transparent substrate 12. Light emitted by phosphor layer 20-2 is emitted in the opposite direction, towards and through clear coat encapsulation 26.
    [0056] In one embodiment of the present invention, the process of Fig. 2 can be slightly rearranged to produce an EL 90 lamp on top of a generally transparent substrate 12, as shown in Fig. 13. Substrate 12 is selected. in s102. If substrate 12 is electrically conductive an electrically insulating, generally transparent form of primer layer 14 d s104 can be applied to the substrate. One or more busbars 24 of s118 are applied over substrate 12 (or primer layer 14). The transparent electrode layer 22 of s120 is applied over busbar 24 and substrate 12 (or primer layer 14). The 20 phosphor film layer of s114 is applied over the electrode film layer 22. The dielectric film layer 18 of s112 is applied over the phosphor layer. The electrically conductive film base backplane layer 16 of s104 is applied over the dielectric film layer 18. Alternatively, a second globally transparent electrode layer 22 can be replaced by the base backplane film layer 16 of s104. The electrical connections of the s108 can be made in any manner described above. When constructed in this way, light emitted by the phosphor film layer 20 radiates through the transparent electrode layer 22 and the transparent substrate 12. The EL lamp 90 is another form similar to the EL lamp 10, described above.
    [0057] A number of mechanisms and additives can be used to alter and/or improve the appearance of EL lamps produced in accordance with the present invention, delineated by whether a specific additive provides either a significantly passive, active or emissive function. Firstly, passive additives can be used. A passive additive is by definition an integrated component to the coating layers of any of the Lamp ELs 10, 50, 60, 70, 80, 90 such that it does not emit light as a matter of function, but modifies the emitted light. to expose a desired quality. There are a number of materials, both naturally occurring and engineered, that can be used to take advantage of birefringent/polarization/crystal optical properties to substantially improve color and/or apparent luminosity by employing a modified Fresnel lens effect.
    [0058] An active additive is a material that does not emit light, but modifies light through the application of an electric field. A number of natural materials and a growing family of engineering materials, particularly polymers, exhibit significant electro-optical characteristics, in particular the modification of a material's optical properties by the application of an electric field. Electrochromism, the ability of a material to change color due to the application of electrical charge is of particular interest among these effects. Such materials can be incorporated with the phosphor layer copolymer 20 or as a distinct layer between the phosphor and top electrode 22 layers.
    [0059] Recent advances in EL materials engineering promise to further improve the performance of EL lamps produced in accordance with the present invention by complementing or replacing the doped ZnS component of the base formula for the phosphor layer 20. Among others, gallium nitride (GaN), gallium sulphide (gas), gallium (GaSe2) and strontium aluminate (SRAL) compounds doped with various metal trace elements have shown value as EL materials.
    [0060] Another material that can be used to complement or replace the ZnS-doped component of the base formula for the phosphor layer 20 is quantum dots. Quantum Dots are a relatively new technology, which introduce a new emissive mechanism to the EL material family. Instead of an emitter of a certain bandwidth (color) of light based on characteristics of the doping material, the emission frequency is determined by the actual physical size of the particles and thus can be "tuned" to emit light through a broad spectrum, including near infrared. Quantum Dots also feature both photoluminescent as well as electroluminescent characteristics. These features offer a number of potential functional benefits for EL lamps produced in accordance with the present invention from either traditional EL materials composition with quantum dots or replacing traditional materials entirely with Quantum Dot technology, depending on functional requirements.
    [0061] While this invention has been shown and described with respect to a detailed embodiment thereof, it will be understood by those skilled in the art that changes in form and detail thereof can be made without departing from the scope of the claims of the invention.
    权利要求:
    Claims (18)
    [0001]
    1. Process to produce a shaped electroluminescent system, characterized by comprising the steps of: selecting a substrate; applying a base backplane film layer to the substrate using an electrically conductive water-based backplane material; applying a dielectric film layer over the backplane film layer using a water-based dielectric material; apply a phosphor film layer to the dielectric film layer using a water-based phosphor material, the phosphor film layer being excited by an ultraviolet radiation source during application, the ultraviolet radiation source providing visual cues while the layer of the phosphor film being applied, the application of the phosphor film layer being adjusted in response to visual signals during the phosphor application step to apply a generally uniform distribution of the phosphor material over the dielectric film layer; and applying an electrode film layer over the phosphor film layer using a water-based, substantially transparent, electrically conductive electrode material, each of the backplane film layer, dielectric film layer, phosphor film layer and layer. of electrode film being applied by shaped spray coating, wherein the phosphor film layer is excitable by an electric field established through the phosphor film layer under application of an electrical charge between the backplane film layer and the phosphor layer. electrode film, such that the phosphor film layer emits electroluminescent light.
    [0002]
    2. Process according to claim 1, characterized in that it further includes the step of selecting a dielectric material having both electrically insulating and permitting properties, the dielectric material further comprising at least one of a titanate, an oxide, a niobate, an aluminate, a tantalate and a zirconate material, the additional dielectric material being suspended in an aqueous ammonia solvent.
    [0003]
    Process according to claim 1, further including the step of formulating a composition for the dielectric film layer, which comprises: providing a 2:1 solution of copolymer and dilute ammonium hydroxide; pre-wetting a predetermined amount of barium titanate in a predetermined amount of ammonium hydroxide; and adding the pre-wetted barium titanate to the solution of copolymer and dilute ammonium hydroxide to form a supersaturated suspension.
    [0004]
    4. Process according to claim 1, characterized in that it additionally includes the step of selecting a dielectric material having electrically insulating and permitting properties, the dielectric material also having photorefractive properties to facilitate the propagation of light through superimposed layers of the device.
    [0005]
    The process of claim 1, further including the step of selecting, for the phosphor material, a semi-conductive coating composition having phosphors encapsulated within a highly electrostatically permeable polymer matrix.
    [0006]
    6. Process according to claim 1, characterized in that it additionally includes the step of selecting, for the phosphor material, a coating composition containing quantum dots or zinc sulfide-based phosphors doped with at least one of copper, manganese and silver.
    [0007]
    7. Process for the production of a shaped electroluminescent system, characterized by comprising the steps of: selecting a generally transparent substrate; applying an electrode film layer over the substrate using a substantially transparent, electrically conductive, water-based electrode material; apply a phosphor film layer over the electrode film layer using a water-based phosphor material, the phosphor film layer being excited by an ultraviolet radiation source during application, the ultraviolet radiation source providing visual cues while the phosphor film layer being applied, the application of the phosphor film layer being adjusted in response to visual signals during the phosphor application step to apply a generally uniform distribution of the phosphor material over the electrode film layer; applying a dielectric film layer over the phosphor layer using a water-based dielectric material; and applying a base backplane film layer over the dielectric film layer using an electrically conductive, water-based backplane material; each of the backplane film layer, dielectric film layer, phosphor film layer and electrode film layer being applied by spray shaped coating, wherein the phosphor film layer is excitable by an electric field established across the phosphor film layer under the application of an electrical charge between the backplane film layer and the electrode film layer such that the phosphor film layer emits electroluminescent light.
    [0008]
    8. Process according to claim 7, characterized by further including the step of selecting a dielectric material having both electrically insulating and permitting properties, the dielectric material further comprising at least one of a titanate, an oxide, a niobate, an aluminate, a tantalate and a zirconate material, the additional dielectric material being further suspended in an aqueous ammonia solvent.
    [0009]
    The process of claim 7, further including the step of formulating a composition for the dielectric film layer, comprising: providing about a 2:1 solution of copolymer and dilute ammonium hydroxide; pre-wetting a predetermined amount of barium titanate in a predetermined amount of ammonium hydroxide; and adding the pre-wetted barium titanate to the solution of copolymer and dilute ammonium hydroxide to form a supersaturated suspension.
    [0010]
    10. Process according to claim 7, characterized in that it additionally includes the step of selecting a dielectric material having electrically insulating and permitting properties, the dielectric material also having photorefractive properties to facilitate the propagation of light through superimposed layers of the device.
    [0011]
    11. The process of claim 7, further including the step of selecting, for the phosphor material, a semiconductor coating composition having phosphors encapsulated within a highly electrostatically permeable polymer matrix.
    [0012]
    Process according to claim 7, characterized in that it additionally includes the step of selecting, for the phosphor material, a coating composition containing quantum dots or phosphors based on zinc sulfide doped with at least one of copper, manganese and silver.
    [0013]
    13. Process for the production of a shaped electroluminescent system, characterized by comprising the steps of: selecting a generally transparent substrate; applying a first layer of electrode film onto the substrate using a substantially transparent, water-based, electrically conductive electrode material; applying a first layer of phosphor film over the first layer of electrode film using a water-based phosphor material, the first layer of phosphor film being excited by an ultraviolet radiation source during application, the ultraviolet radiation source providing visual cues while the first phosphorus film layer is being applied, the application of the first phosphorus film layer being adjusted in response to visual signals during the phosphorus application step to apply a generally uniform distribution of the phosphor material over the first electrode film layer; applying a dielectric film layer over the first phosphor film layer using a water-based dielectric material; apply a second phosphor film layer over the dielectric film layer using the phosphor material, the second phosphor film layer being excited by an ultraviolet radiation source during application, the ultraviolet radiation source providing visual cues while the second phosphorus film layer being applied, the application of the second phosphorus film layer being adjusted in response to visual signals during the phosphorus application step to apply a generally uniform distribution of the phosphor material over the dielectric film layer; and applying a second electrode film layer over the second phosphor film layer using the electrode material, each of the first electrode film layer, first phosphor film layer, dielectric film layer, second phosphor film layer, phosphor and second electrode film layer being applied by shaped spray coating. wherein the first and second phosphor film layers are excitable by an electric field established between the first and second phosphor film layers under the application of an electrical charge between the first electrode film layer and the second electrode film layer. electrode, such that the device emits electroluminescent light, the electroluminescent light being emitted on opposite sides of the substrate.
    [0014]
    Process according to claim 13, characterized in that it further includes the step of selecting a dielectric material having both electrically insulating and permitting properties, the dielectric material further comprising at least one of a titanate, an oxide, a niobate , an aluminate, a tantalate, and a zirconate material, the dielectric material being further suspended in an aqueous ammonia solvent.
    [0015]
    15. The process of claim 13, further including the step of formulating a composition for the dielectric film layer, which comprises: providing an approximately 2:1 solution of copolymer and dilute ammonium hydroxide; pre-wetting a predetermined amount of barium titanate in a predetermined amount of ammonium hydroxide; and adding the pre-wetted barium titanate to the copolymer solution and dilute ammonium hydroxide to form a supersaturated suspension.
    [0016]
    16. Process according to claim 13, characterized in that it additionally includes the step of selecting a dielectric material having electrically insulating and permitting properties, the dielectric material further having photorefractive properties to facilitate the propagation of light through superimposed layers of the device.
    [0017]
    17. The process of claim 13, further including the step of selecting, for the phosphor material, a semiconductor coating composition having phosphors encapsulated within a highly electrostatically permeable polymer matrix.
    [0018]
    18. Process according to claim 13, characterized in that it further includes the step of selecting, for the phosphor material, a coating composition containing quantum dots or phosphorus based on zinc sulfide doped with at least one of copper, manganese and silver.
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    同族专利:
    公开号 | 公开日
    EP2801242A1|2014-11-12|
    AU2013207081C1|2015-10-01|
    NZ628041A|2014-12-24|
    HK1201398A1|2015-08-28|
    BR112014016393A8|2017-07-04|
    US20130171903A1|2013-07-04|
    KR20140123059A|2014-10-21|
    EP2801242A4|2015-07-22|
    WO2013102859A1|2013-07-11|
    CN104115561B|2017-03-01|
    JP2015503829A|2015-02-02|
    JP2017224620A|2017-12-21|
    PH12014501393B1|2014-10-08|
    MX2014007900A|2015-02-04|
    MY170084A|2019-07-04|
    SG11201403300XA|2014-07-30|
    CN104115561A|2014-10-22|
    RU2639294C2|2017-12-21|
    MX336165B|2016-01-11|
    BR112014016393A2|2017-06-13|
    KR102232550B1|2021-03-30|
    JP6185481B2|2017-08-23|
    PL2801242T3|2017-05-31|
    AU2013207081A1|2014-07-24|
    CA2862546C|2020-05-12|
    AU2013207081B2|2015-04-30|
    PH12014501393A1|2014-10-08|
    RU2014131955A|2016-02-20|
    EP2801242B1|2016-09-14|
    ES2616799T3|2017-06-14|
    US20130171754A1|2013-07-04|
    US8470388B1|2013-06-25|
    IN2014DN05725A|2015-04-10|
    WO2013102859A4|2013-10-10|
    CA2862546A1|2013-07-11|
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    法律状态:
    2018-05-02| B25A| Requested transfer of rights approved|Owner name: DARKSIDE SCIENTIFIC, LLC (US) |
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-11-05| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-05-04| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-06-01| B350| Update of information on the portal [chapter 15.35 patent gazette]|
    2021-06-29| B25D| Requested change of name of applicant approved|Owner name: DARKSIDE SCIENTIFIC, INC (US) |
    2021-07-06| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 03/01/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    2021-07-13| B25G| Requested change of headquarter approved|Owner name: DARKSIDE SCIENTIFIC, INC (US) |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261582581P| true| 2012-01-03|2012-01-03|
    US61/582,581|2012-01-03|
    US13/624,910|US20130171903A1|2012-01-03|2012-09-22|Electroluminescent devices and their manufacture|
    US13/624,910|2012-09-22|
    US13/677,864|2012-11-15|
    US13/677,864|US8470388B1|2012-01-03|2012-11-15|Electroluminescent devices and their manufacture|
    PCT/IB2013/050037|WO2013102859A1|2012-01-03|2013-01-03|Electroluminescent devices and their manufacture|
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