Process for roll-to-roll manufacture of a display by...

G - Physics – 03 – F

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G03F 7/20 (2006.01) G02F 1/1333 (2006.01) G02F 1/167 (2006.01) G03F 7/24 (2006.01) G03F 7/00 (2006.01)

Patent

CA 2437411

This invention relates to an electrophoretic display or a liquid crystal display and novel processes for its manufacture. The electrophoretic display (EPD) of the present invention comprises microcups of well-defined shape, size and aspect ratio and the microcups are filled with charged pigment particles dispersed in an optically contrasting dielectric solvent. The liquid crystal display (LCD) of this invention comprises well-defined microcups filled with at least a liquid crystal composition having its ordinary refractive index matched to that of the isotropic cup material. A novel roll-to-roll process and apparatus of the invention permits the display manufacture to be carried out continuously by a synchronized photo-lithorgrahic process. The synchronized roll-to-roll process and apparatus permits a pre-patterned photomask, formed as a continuous loop, to be rolled in a synchronized motion in close parallel alignment to a web which has been pre-coated with a radiation sensitive material, so as to maintain image alignment during exposure to a radiation source. The radiation sensitive material may be a radiation curable material, in which the exposed and cured portions form the microcup structure. In an additional process step, the radiation sensitive material may be a positively working photoresist which temporarily seals the microcups. Exposure of a selected subset of the microcups via the photomask image permits selective re-opening, filling and sealing of the microcup subset. Repetition with additional colors permits the continuous assembly of a multicolor EPD or LCD display.

L'invention concerne un affichage électrophorétique ou un affichage à cristaux liquides et de nouveaux procédés de fabrication. L'affichage électrophorétique (EPD) de la présente invention comprend des micro-cellules de forme, dimension et facteur de forme bien définis, remplies de particules pigmentaires chargées dispersées dans un solvant diélectrique de contraste optique. L'affichage à cristaux liquides (LCD) de l'invention comprend des micro-cellules bien définies remplies d'au moins une composition à cristaux liquides dont l'indice de réfraction ordinaire correspond à celui du matériau de la cellule isotrope. Le nouveau procédé et l'appareil <=roll-to-roll>= de l'invention permettent de procéder à la fabrication de l'affichage en continu par un procédé photolithographique synchronisé. Le procédé et l'appareil <=roll-to roll>= synchronisé permettent d'enrouler un photomasque pré-modélisé formant une boucle continue en un mouvement synchronisé en alignement parallèle avec une bande revêtue au préalable d'un matériau sensible au rayonnement, de manière à maintenir l'alignement de l'image pendant l'exposition à une source de rayonnement. Le matériau sensible au rayonnement peut être une photorésine positive fermant temporairement les micro-cellules. L'exposition d'un sous-ensemble sélectionné de micro-cellules via l'image à photomasque permet de réouvrir, remplir et fermer de manière sélective le sous-ensemble de micro-cellules. La répétition avec des couleurs supplémentaires permet d'assembler en continu un affichage EPD ou LCD multicolore.

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