Electroluminescence device and manufacturing method therefor

Abstract

The present invention relates to an electroluminescence device and a manufacturing method therefor. The electroluminescence device comprises: a substrate; a conductive layer on the surface of the substrate, wherein the conductive layer comprises a busbar layer and a sub-line layer, and a gap region is present between the busbar layer and the sub-line layer; a dielectric layer on the surface of the busbar layer of the conductive layer, wherein the dielectric layer covers the side surface of the busbar layer adjacent to the gap region and covers at least a portion of the gap region; a light-emitting layer on the surface of the dielectric layer; and a transparent conductive layer on the surface of the light-emitting layer, wherein the transparent conductive layer covers the side surfaces of the light-emitting layer and the dielectric layer facing the sub-line layer and the side surface of the sub-line layer adjacent to the gap region and covers the surface of the sub-line layer.

Description

Electroluminescent device and manufacturing method thereof Technical Field

[0001] This invention belongs to the field of optoelectronic technology, and particularly relates to electroluminescent devices and their manufacturing methods. Background Technology

[0002] Currently, electroluminescent (EL) technology is widely used in display devices. Its relatively low power consumption, relatively high brightness, and ability to be formed in relatively thin film configurations have demonstrated its superiority over light-emitting diodes (LEDs) and incandescent technology used in many applications. Furthermore, domestic and international manufacturers have developed electroluminescent systems or improved methods with different structures.

[0003] Patent document 1 (publication number CN104115561A) discloses a method for manufacturing a conformal electroluminescent system. Each film layer is made of water-based functional materials and is prepared by spray conformal coating method. However, the following problems exist: (1) Each film layer is prepared by spray conformal coating method, which is prone to unclear coating boundary, resulting in inaccurate electrical structure; (2) The structure design of the electroluminescent system is complicated, especially the electrode connection power supply (such as AC signal) uses conductive strips; (3) Since the spray process in (1) is characterized by boundaryless uniform coating, when the coating needs clear boundary (i.e., when conductive strip is set in (2)), complex manual or equipment intervention is required. Moreover, these operations (setting conductive strip) need to be performed on the fragile and high-cleanliness coated coating, which causes great process difficulty and risk. Moreover, this operation is repeated multiple times in the patent document, resulting in a production time (i.e., labor hours) of more than 18 hours required to produce a complete electroluminescent device, a low yield rate (as low as 60%), poor stability (the conductive strip requires manual contact with the fragile electrical coating surface), and high cost (high labor hours, high material loss, and low yield).

[0004] Patent document 2 (publication number CN109844896A) discloses an electroluminescent system and process, specifically involving a conformal coating applied by spraying. This coating uses high-pressure low-capacity spraying, aerosol spraying, or electrostatic spraying to coat each film layer. However, it still suffers from unclear coating boundaries, leading to inaccurate electrical structures. Furthermore, patent document 2 does not disclose how the two electrodes in the electroluminescent system are connected to the AC signal, nor does it disclose how the electroluminescent system is packaged.

[0005] Patent document 3 (authorization announcement number CN212556094U) discloses a grid decorative strip that can emit light on its own. It uses a bus layer and a sub-line layer to connect two electrodes of alternating current. However, the sub-line layer is located inside the transparent conductive layer, and a dielectric layer and a light-emitting layer are provided between the bus layer and the sub-line layer. It still belongs to the category of traditional electroluminescent system structure.

[0006] In summary, existing electroluminescent systems have at least one of the following problems: (1) unclear coating boundaries, resulting in inaccurate electrical structure; (2) complex device structure, especially the use of conductive strips for electrode connection to power supply (such as AC signal); (3) due to the unclear coating boundaries of existing electroluminescent systems and the repeated operation of setting conductive strips, the production time required for a complete electroluminescent device is as high as 18 hours or more, the yield rate of one-time production is low, the stability is poor, and ultimately the cost of electroluminescent systems is high. Summary of the Invention

[0007] In view of the problems existing in the existing electroluminescent systems, the purpose of this invention is to provide an electroluminescent device with a novel structure and a method for manufacturing the same, so as to significantly improve the lifespan of the electroluminescent device.

[0008] A first aspect of the present invention provides an electroluminescent device, comprising:

[0009] Substrate;

[0010] A conductive layer on the surface of a substrate, the conductive layer comprising a busbar layer and a sub-busbar layer, wherein there is a gap between the busbar layer and the sub-busbar layer;

[0011] A dielectric layer on the surface of the busbar layer of the conductive layer, a portion of which covers one side of the busbar layer adjacent to the spacer region and covers at least a portion of the spacer region;

[0012] A light-emitting layer on a dielectric layer;

[0013] A transparent conductive layer on the light-emitting layer, a portion of which covers one side of the light-emitting layer and the dielectric layer facing the sub-line layer and the side of the sub-line layer adjacent to the spacer region, and covers another portion of the sub-line layer and the spacer region.

[0014] Preferably, the dielectric layer covers the entire spacer region, and a portion of the transparent conductive layer covers the light-emitting layer and the dielectric layer on one side of the sub-line layer and covers the sub-line layer.

[0015] Preferably, both the busbar layer and the sub-busbar layer are formed of an oily / grease-based conductive material; more preferably, the oily / grease-based conductive material comprises an adhesive material and metal nanoparticles, wherein the adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, most preferably polyurethane material, and the metal nanoparticles comprise copper nanoparticles and / or silver nanoparticles.

[0016] Preferably, the dielectric layer is formed of an oily / grease-based dielectric material; more preferably, the oily / grease-based dielectric material comprises an adhesive material and ceramic capacitor nanoparticles, wherein the adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, most preferably comprising polyurethane material, and the ceramic capacitor nanoparticles comprise at least one of barium titanate, lithium barium titanate, zirconium oxide, and lead zirconium titanate.

[0017] Preferably, the light-emitting layer is formed of an oily / grease-based luminescent material; more preferably, the oily / grease-based luminescent material comprises an adhesive material and an intrinsic luminescent material, wherein the adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, most preferably polyurethane material, and the intrinsic luminescent material comprises at least one of zinc sulfide, zinc selenide, calcium antimonate, and aluminum 8-hydroxyquinoline.

[0018] Preferably, the transparent conductive layer is formed of an aqueous transparent conductive material; preferably, the transparent conductive material comprises a conjugated polymeric conductive polymer and / or carbon nanotubes, wherein the conjugated polymeric conductive polymer comprises at least one of poly(3,4-ethylenedioxythiophene), polyaniline, and polythiophene.

[0019] Preferably, the thickness of the busbar layer is 0.02 to 0.04 mm, more preferably 0.0254 to 0.0381 mm, and even more preferably 0.03 mm.

[0020] Preferably, the thickness of the sub-line layer is 0.02 to 0.04 mm, more preferably 0.0254 to 0.0381 mm, and even more preferably 0.03 mm.

[0021] Preferably, the length of the interval between the busbar area and the sub-busbar area is ≥0.3mm, which is determined by the laser engraving precision.

[0022] Preferably, the surface precision of the busbar layer and the sub-busbar layer is 5 to 15 GU.

[0023] Preferably, the boundary accuracy of the side of the interval adjacent to the busbar layer and / or the side adjacent to the sub-line layer is ≤0.1mm.

[0024] Preferably, the thickness of the dielectric layer is 0.02 to 0.04 mm, more preferably 0.0254 to 0.0381 mm, and even more preferably 0.03 mm. This thickness is the coating thickness of the dielectric layer on the surface of the busbar layer.

[0025] Preferably, the thickness of the light-emitting layer is 0.02 to 0.04 mm, and more preferably 0.0254 to 0.0381 mm.

[0026] Preferably, the thickness of the transparent conductive layer is ≥0.01mm, more preferably 0.01mm to 0.02mm, more preferably 0.01 to 0.015mm, and most preferably 0.01mm. This thickness is the coating thickness of the transparent conductive layer on the light-emitting layer.

[0027] Preferably, the total thickness of the busbar layer, dielectric layer, light-emitting layer and transparent conductive layer does not exceed 0.15 mm, and is more preferably 0.07 to 0.135 mm.

[0028] Preferably, the electroluminescent device further includes a primer layer between the substrate and the conductive layer; more preferably, the primer layer comprises epoxy resin and abrasive; even more preferably, the thickness of the primer layer is 0.02-0.04 mm, preferably 0.02-0.03 mm.

[0029] Preferably, the electroluminescent device further includes a controller connecting (e.g., electrically connecting) the bus layer and the sub-line layer, the controller outputting an AC signal. More preferably, the positive and negative terminals of the controller are connected to the bus layer and the sub-line layer by conductive adhesive in a contacting or bonding manner. Specifically, after the contacts are attached to the prepared coatings (bus layer and sub-line layer) with conductive adhesive, the positive / negative terminals are connected to the bus layer and the sub-line layer by contacting or bonding. Since the controller is AC driven, the positive terminal can be connected to the bus layer and the negative terminal can be connected to the sub-line layer; or the positive terminal can be connected to the sub-line layer and the negative terminal can be connected to the bus layer.

[0030] Preferably, the electroluminescent device further includes a varnish layer formed on the transparent conductive layer; more preferably, the varnish layer is composed of varnish, which is composed of epoxy resin and organic solvent; even more preferably, the thickness of the varnish layer is 0.02-0.06 mm, preferably 0.04-0.06 mm.

[0031] Preferably, the electroluminescent device further includes a colored paint layer formed on the transparent conductive layer or a colored paint layer formed between the transparent conductive layer and the clear varnish layer; more preferably, the colored paint layer is formed of epoxy resin and mortar; more preferably, the thickness of the colored paint layer is 0.02-0.1 mm, preferably 0.02-0.04 mm, and more preferably 0.04 mm.

[0032] Preferably, the total thickness of the busbar layer, dielectric layer, light-emitting layer, transparent conductive layer, paint layer and varnish layer is no more than 0.35 mm, preferably no more than 0.335 mm, more preferably no more than 0.3 mm, and most preferably no more than 0.25 mm.

[0033] Preferably, the electrical half-life of the electroluminescent device is more than 2000 hours.

[0034] A second aspect of the present invention provides a method for manufacturing the above-described electroluminescent device, comprising the following steps:

[0035] (1) Coat the substrate surface with conductive paint to form a conductive layer;

[0036] (2) Using laser engraving process, a portion of the conductive layer is engraved until the substrate surface is exposed, forming a busbar layer and a sub-busbar layer and an interval area between the busbar layer and the sub-busbar layer.

[0037] (3) Apply capacitor paint to the surface of the busbar layer and one side of the adjacent interval area of ​​the busbar layer to form a dielectric layer;

[0038] (4) Coat the surface of the dielectric layer with luminescent paint to form a luminescent layer;

[0039] (5) A transparent conductive paint is coated on the surface of the light-emitting layer, the surface of the sub-line layer, the surface of the light-emitting layer and the dielectric layer facing the sub-line layer, and the surface of the sub-line layer adjacent to the spacer region to form a transparent conductive layer, thereby producing an electroluminescent device.

[0040] Preferably, the manufacturing method further includes coating a primer layer on the surface of the substrate before step (1), preferably, the primer layer is formed by a primer comprising epoxy resin, abrasive and organic solvent.

[0041] Preferably, the conductive paint comprises an organic solvent, an adhesive material, and metal nanoparticles, wherein the adhesive material comprises a polyurethane material, the metal nanoparticles comprise copper nanoparticles and / or silver nanoparticles, and the organic solvent comprises at least one of butyl acetate, xylene, and trimethylbenzene.

[0042] Preferably, in step (2): the length of the interval region (i.e., radial gap) between the busbar layer and the sub-line layer is ≥0.3mm; the surface accuracy of the busbar layer and the sub-line layer is 5~15GU.

[0043] Preferably, the engraving parameters include: laser power of 30-40W, scanning speed of 800-1200mm / s, pulse frequency of 20KHz-30KHz, and spot diameter of 80-100μm. This invention, by setting specific engraving parameters, ensures that the boundary accuracy of the side adjacent to the busbar layer and / or the side adjacent to the sub-line layer in the interval is ≤0.1mm (i.e., the error in the width of the interval is ≤±0.1mm; the testing method is: using a standard ruler to measure the width of the interval every 50-200mm, and after 5 measurements, calculate the average value; the difference between this average value and the set value).

[0044] Preferably, in step (3), the capacitor paint comprises an organic solvent, an adhesive material, and ceramic capacitor nanoparticles. The adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material. The ceramic capacitor nanoparticles comprise at least one of barium titanate, lithium barium titanate, zirconium oxide, and lead zirconium titanate.

[0045] Preferably, in step (4), the luminescent paint comprises an organic solvent, an adhesive material, and an intrinsic luminescent material. The adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material. The intrinsic luminescent material comprises at least one of zinc sulfide, zinc selenide, calcium antimonate, and aluminum 8-hydroxyquinoline. The organic solvent comprises at least one of butyl acetate, xylene, and trimethylbenzene.

[0046] Preferably, in step (5), the transparent conductive paint comprises at least one of carbon nanotubes and a conjugated polymeric conductive polymer, and a solvent; the solvent comprises an organic solvent and / or deionized water, the organic solvent comprises at least one of isopropanol and ethanol, the conjugated polymeric conductive polymer comprises at least one of poly(3,4-ethylenedioxythiophene), polyaniline and polythiophene, and the organic solvent comprises at least one of butyl acetate, xylene and trimethylbenzene.

[0047] Preferably, the manufacturing method further includes:

[0048] Step (6): Coat the surface of the transparent conductive layer with colored paint to form a colored paint layer; and / or coat the surface of the transparent conductive layer with varnish to form a varnish layer.

[0049] More preferably, the paint comprises epoxy resin, mortar, and organic solvent (the organic solvent comprises at least one or more of butyl acetate, xylene, and trimethylbenzene).

[0050] More preferably, the varnish is composed of an epoxy resin and an organic solvent (the organic solvent comprises at least one or more of butyl acetate, xylene, and trimethylbenzene).

[0051] Preferably, the manufacturing method further includes step (7): coating a clear varnish on the surface of the paint layer to obtain a clear varnish layer; more preferably, the clear varnish is formed from an epoxy resin and an organic solvent (the organic solvent comprises at least one or more of butyl acetate, xylene, and trimethylbenzene).

[0052] Preferably, the manufacturing method further includes: controller installation: attaching contacts to the busbar layer and sub-busbar layer respectively with conductive adhesive, and connecting the positive and negative terminals of the controller to the busbar layer and sub-busbar layer by abutting or attaching to the contacts.

[0053] The beneficial effects of this invention are:

[0054] This invention enhances material adhesion and improves interlayer adhesion and water and oxygen isolation capabilities by improving interlayer processes (e.g., by specifically setting the polarity and compatibility between materials in each layer and by using a conductive layer structure with a specific structure).

[0055] Based on the optimization of the coating structure, this invention introduces laser engraving and photolithography technology to process the conductive layer, and designs a more refined and superior conductive layer structure. The boundary accuracy of the conductive layer structure is improved from the original 5mm to 0.1mm.

[0056] The coating process of the present invention is reduced from the original 5 coatings to 4 coatings, and the most complicated 5th coating masking process is eliminated, thereby reducing the structural complexity of the electroluminescent device and reducing material costs.

[0057] This invention reduces the amount of precious metals used by optimizing basic materials;

[0058] This invention reduces the need for repeated color spraying and optimizes the process by improving the coating structure. This significantly reduces the time required to produce a complete electroluminescent device (i.e., labor time, single-piece process time ≤ 3h, preferably ≤ 2h), improves the yield (≥90%) and stability (≥95%), and greatly reduces costs. Attached Figure Description

[0059] Figure 1 shows a schematic diagram of the structure of an electroluminescent device according to an embodiment of the present invention;

[0060] Figure 2 shows a schematic diagram of the structure of an electroluminescent device according to another embodiment of the present invention;

[0061] Figure 3 shows a schematic diagram of the structure of an electroluminescent device according to another embodiment of the present invention;

[0062] Figure 4 shows a schematic diagram of the structure of an electroluminescent device containing a controller according to an embodiment of the present invention. Detailed Implementation

[0063] In order to better understand the above technical solutions of the present invention, the structure and manufacturing process of the electroluminescent device of the present invention will be further described and explained below in conjunction with the accompanying drawings and specific embodiments. This description and explanation should not be construed as limiting the scope of protection of the present invention in any way.

[0064] It should be noted that the directional or orientational concepts such as up, down, left, right, front, back, top, and bottom mentioned in this article refer to the current positional state of Figures 1-3 and should not be construed as a special limitation on the technical solution provided by this invention.

[0065] As shown in Figure 1, the structure of an electroluminescent device according to an embodiment of the present disclosure includes, from bottom to top: a substrate (which may be selectively coated with a primer layer), a conductive layer (including a busbar layer and a sub-busbar layer), a spacer region located between the busbar layer and the sub-busbar layer, a dielectric layer (or capacitor layer), a light-emitting layer, and a transparent conductive layer.

[0066] In this disclosure, the material of the substrate is not particularly limited and can be those commonly used in the art, including but not limited to plastics, metals, wood, glass, etc., for the purpose of supporting the various functional layers. The substrate can be an existing device or part, such as an automotive part. Preferably, the surface of the substrate further includes a primer layer (the primer layer includes epoxy resin and a binder), which serves to establish a foundation for adhesion of the underlying layer and to provide a uniform application surface for the electrical functional coatings above. Preferably, the primer layer is formed by a primer. The primer includes epoxy resin, a binder, and an organic solvent. The epoxy resin content in the primer is 60-80 wt%, the binder content is 10-20 wt%, and the balance is an organic solvent. It should be noted that the primer used in this invention involves abrasives for paint pigments and / or masterbatches. These pigments or masterbatches are generally prepared from abrasives of commonly used mineral pigments (responsible for the color components in paint, such as cinnabar for red, pyrite for yellow, malachite for green, and barium oxide for white), and are conventionally referred to as abrasives in the industry. In this invention, the difference between the primer and the paint is actually very small; epoxy primer can be understood as a type of paint.

[0067] Preferably, the thickness of the primer layer is 0.02 to 0.04 mm, and more preferably 0.02 to 0.03 mm.

[0068] In this disclosure, the conductive layer includes a bus layer and a sub-bus layer, with a gap between them, i.e., the exposed portion of the substrate surface not covered by the conductive layer. The bus layer and the sub-bus layer are located on the same horizontal plane and exist independently. The conductive layer is formed of an oil-based / grease-based conductive material, which includes a binder material and metal nanoparticles, serving as electrodes. The binder material includes any one or a combination of two or more of polyurethane, epoxy resin, and polyester resin. The metal nanoparticles include copper nanoparticles and / or silver nanoparticles. The particle size of the metal nanoparticles can be 10–50 nm, preferably 10–30 nm, and more preferably 15–20 nm. For example, the particle size of copper nanoparticles is 15–20 nm, and the particle size of silver nanoparticles is 10–20 nm. In optional embodiments, the mass ratio of binder material to metal nanoparticles in the conductive layer is (5-1.5):1, preferably (4-1.5):1, more preferably (3-1.5):1, and most preferably (2.5-1.5):1. In optional embodiments, the thickness of both the busbar layer and the sub-line layer can be 0.02-0.04 mm, and may be the same or different. The length of the spacing region (i.e., the shortest distance between the busbar layer and the sub-line layer) is ≥0.3 mm, for example, preferably 0.5-2 mm. The spacing between the busbar and sub-line layers can be measured with a standard ruler. In practice, the distance between the sub-line layer and the busbar varies greatly in different application scenarios; as long as it is maintained at least 0.3 mm (laser engraving precision) or higher (if necessary, it can even reach several hundred to several thousand millimeters, for example, 500 mm to 1000 mm), it is acceptable. The surface precision of the busbar layer and the sub-line layer is at least 5-15 GU.

[0069] In this disclosure, a dielectric layer is formed on the busbar layer and a portion of the spacer region, wherein the dielectric layer covers the surfaces of the busbar layer and the portion of the spacer region and encapsulates the side surfaces of the busbar layer adjacent to the spacer region. This dielectric layer facilitates coating, significantly reduces process difficulty, improves production yield and efficiency, and provides a more efficient and safer electrical structure. The dielectric layer is formed of an oil-based / grease-based dielectric material, which includes an adhesive material and ceramic capacitor nanoparticles. The adhesive material includes any one or a combination of two or more of polyurethane, epoxy resin, and polyester resin. The ceramic capacitor nanoparticles include at least one of barium titanate, barium lithium titanate, zirconium oxide, and barium lead zirconate titanate. The particle size of the ceramic capacitor nanoparticles can be 100 nm to 500 nm, preferably 200 nm to 500 nm, and more preferably 250 nm to 300 nm. In an optional embodiment, the mass ratio of the binder material to the ceramic capacitor nanopowder is (5-1):1, preferably (4-1):1, more preferably (3-1.5):1, and most preferably (2-1):1. In an optional embodiment, the thickness of the dielectric layer can be 0.02-0.04 mm.

[0070] In this disclosure, the light-emitting layer is formed of an oily / grease-based luminescent material, which comprises a binder material and an intrinsic luminescent material. The binder material comprises a polyurethane material. The intrinsic luminescent material comprises at least one of zinc sulfide, zinc selenide, calcium antimonate, and aluminum 8-hydroxyquinoline. The intrinsic luminescent material may be a particulate material with a particle size of 500 nm to 5 μm, preferably 1 to 4 μm, and more preferably 2 to 3 μm. In an optional embodiment, the mass ratio of the binder material to the intrinsic luminescent material is (5 to 1):1, preferably (4 to 1.5):1, more preferably (3 to 1.5):1, and most preferably (2.5 to 2):1. In an optional embodiment, the thickness of the light-emitting layer is 0.02 to 0.04 mm.

[0071] In this disclosure, if the dielectric layer completely covers the surface of the spacer region, a transparent conductive layer is coated and formed on the surface of the light-emitting layer, the surface of the sub-line layer, and the surface of the light-emitting layer and the dielectric layer facing the sub-line layer. If the dielectric layer does not completely fill the spacer region, a portion of the transparent conductive layer covers the surface of the spacer region not covered by the dielectric layer and encapsulates the surface of the sub-line layer adjacent to the spacer region. The transparent conductive layer is formed of an aqueous transparent conductive material comprising a conjugated polymeric conductive polymer and / or carbon nanotubes. The conjugated polymeric conductive polymer comprises at least one of poly(3,4-ethylenedioxythiophene), polyaniline, and polythiophene. In an optional embodiment, the thickness of the transparent conductive layer is ≥0.01 mm (e.g., ≥0.0127 mm), preferably less than 0.02 mm. In an optional embodiment, the total thickness of the busbar layer, dielectric layer, light-emitting layer, and transparent conductive layer does not exceed 0.15 mm, preferably 0.07–0.135 mm.

[0072] This invention achieves an ultra-thin design for electroluminescent devices, while still maintaining an electrical half-life of at least 2000 hours within this thickness range. Specifically, the electroluminescent device of this invention achieves a significantly improved electrical half-life through the synergistic effects of configuring the conductive layers as bus layers and sub-bus layers and driving them by applying an alternating current signal between them, using luminescent materials with specific compositions, and specifically setting the thickness of each layer.

[0073] As shown in Figures 2-4, another embodiment of the electroluminescent device of the present invention further includes: a colored paint layer (such as a car body paint layer, etc.) and / or a clear coat layer (or a protective layer, protective clear coat layer, etc.) formed on the surface of the transparent conductive layer. The inclusion of the colored paint layer and clear coat layer primarily enhances the user experience of the product itself, improving both the electrical half-life of the electroluminescent device (from over 2000 hours to over 3000 hours) and its weather resistance (e.g., resistance to ultraviolet radiation, friction, corrosion, etc.).

[0074] In an optional embodiment, the main components of the paint layer are epoxy resin and abrasive. Preferably, the thickness of the paint layer is 0.02–0.1 mm (e.g., 0.0508 mm). The paint layer is formed from paint. The epoxy resin content in the paint is 60–80 wt%, the abrasive content is 10–20 wt%, and the remainder is organic solvent. It should be noted that the abrasive used in the paint of this invention refers to paint pigments and / or masterbatches. These pigments or masterbatches are generally prepared from abrasives of commonly used mineral pigments (responsible for the color components in paint, such as cinnabar for red, pyrite for yellow, malachite for green, and titanium dioxide for white), and are conventionally referred to as abrasives in the industry. The main components of the clear varnish layer are epoxy resin and organic solvent, wherein the organic solvent includes at least one of butyl acetate, xylene, and trimethylbenzene (different terms for organic solvent and diluent). Preferably, the thickness of the varnish layer is 0.02 to 0.06 mm (e.g., 0.0508 mm), more preferably 0.02 to 0.05 mm, and most preferably 0.03 to 0.05 mm.

[0075] In a preferred embodiment, when additional paint and clear coat layers are provided, the total thickness of the bus layer, dielectric layer, light-emitting layer, transparent conductive layer, paint layer, and clear coat layer in the electroluminescent device does not exceed 0.35 mm, preferably not more than 0.3 mm, and more preferably between 0.2 mm and 0.3 mm. Too thin a coating thickness will result in insufficient electrical performance or incomplete encapsulation, while too thick a coating thickness will result in stress damage, reduced adhesion, and other coating paint quality problems.

[0076] In this disclosure, the spacer region between the busbar layer and the sub-busbar layer is formed using laser engraving lithography. Specifically, a portion of the conductive layer is engraved a second time until the substrate surface is exposed, forming the busbar layer, the sub-busbar layer, and the spacer region between the busbar layer and the sub-busbar layer (i.e., the exposed portion of the substrate surface not covered by the conductive layer). In an optional embodiment, the engraving parameters include: laser power of 30–40 W, scanning speed of 800–1200 mm / s, pulse frequency of 20 kHz–30 kHz, and spot diameter of 80–100 μm. The length (i.e., radial gap) of the spacer region between the busbar layer and the sub-busbar layer is ≥0.3 mm.

[0077] In this disclosure, the coating method for the other layers is not particularly limited and can be any of those commonly used in the art, including but not limited to, high-pressure low-volume spraying technology, aerosol spraying technology, electrostatic spraying technology, etc.

[0078] In this disclosure, contacts are attached to the busbar layer and the sub-busbar layer respectively using conductive adhesive. The positive and negative terminals of the controller are connected to the busbar layer and the sub-busbar layer by abutting or adhering to the contacts. The conductive adhesive used is a conventional reagent in the art (e.g., conductive silver paste (silver powder conductive adhesive), conductive copper paste (copper powder conductive adhesive), inorganic silicate / silver powder composite conductive adhesive, silver powder / copper powder composite conductive adhesive, graphite-filled conductive adhesive), and is commercially available (e.g., Z6011 conductive adhesive, double bond DB2011 conductive adhesive, SINWE conductive adhesive, etc.).

[0079] Performance testing methods:

[0080] A luminance meter was used to test the luminous half-life of the electroluminescent device (i.e., the time required for the luminous intensity of the electroluminescent device to reach 50%).

[0081] The thickness of each layer in the electroluminescent device was measured using a film thickness gauge.

[0082] The anti-ultraviolet performance of the electroluminescent device was tested using an aging test chamber (test conditions: temperature between RT+10℃ (i.e., room temperature plus 10℃) and 70℃, humidity between 45%RH and 70%RH (under light) or above 98%RH (under condensation)); the equivalent exposure time was ≥2000h.

[0083] The impact resistance of the electroluminescent device was tested using a gravel impact testing machine (experimental conditions: temperature: 23℃, number of gravels: 1, pint angle: 90°, gravel type: cobblestone, air pressure: 70psi). SAE J400:2022 standard: result: qualified or unqualified.

[0084] A chemical corrosion chamber was used (sodium chloride content: 50±5g / L; CuCl2·2H2O content: 0.26±0.02g / L; pH value: 3.1-3.3; temperature: 50±2℃; salt spraying volume: 1.5±0.5ml / 80cm). 2 •h), test the corrosion resistance of the electroluminescent device, ISO 9227:2022 standard: result is qualified or unqualified.

[0085] A gloss meter was used to test the surface accuracy of the bus layer and the sub-bus layer in the electroluminescent device.

[0086] Controller: The controller is an ACdrive model manufactured by Platinum Optoelectronics, which outputs AC signals.

[0087] Work time: The total time required to prepare a complete single electroluminescent device, from the initial spraying of each component onto the substrate surface to the completion of controller installation.

[0088] Yield: The percentage of 1000 electroluminescent devices that immediately exhibit electroluminescence function after being subjected to 160V AC voltage (600Hz).

[0089] Stability (or consistency): 200 electroluminescent devices were selected. After being supplied with 160V AC voltage (600Hz), all of them could immediately exhibit electroluminescence function and maintain the proportion of electroluminescence after 2000 hours.

[0090] Examples and Comparative Examples

[0091] Unless otherwise specified, "wt%" and "%" in the following examples and comparative examples refer to weight percentages.

[0092] Example 1

[0093] The electroluminescent device of Example 1 was prepared by a manufacturing method comprising the following steps:

[0094] (1) A primer and a conductive paint are sequentially sprayed onto the substrate surface to form a primer layer and a uniform conductive coating. The primer contains 85% epoxy resin, 10 wt% abrasive material (titanium oxide), and 5 wt% organic solvent (a mixture of butyl acetate, xylene, and methylbenzene). The conductive paint contains 70% polyurethane material, 20% nano-copper powder, and 5% nano-silver powder, with the remainder being a mixture of butyl acetate, xylene, and methylbenzene.

[0095] (2) Using laser engraving process, a portion of the conductive layer is first engraved until the substrate surface is exposed to form an anode region (i.e., busbar layer (thickness of 0.03mm)), a cathode region (i.e., sub-line layer (thickness of 0.03mm)) and a gap region (gap region width of 0.5mm) located between the anode region and the cathode region. The surface accuracy of the obtained busbar layer and sub-line layer is 8Gu, and the accuracy of the two side boundaries of the gap layer is 0.1mm.

[0096] (3) Spray capacitor paint on the surface of the busbar layer and one side of the adjacent interval area of ​​the busbar layer to form a uniform dielectric layer (thickness of 0.03 mm). The capacitor paint contains 50% polyurethane material, 25% ceramic capacitor nanopowder (barium titanate), and the remainder is a mixed solvent of butyl acetate, xylene and trimethylbenzene.

[0097] (4) Spray luminescent paint onto the surface of the dielectric layer to form a uniform luminescent layer (thickness of 0.03 mm), wherein the luminescent paint contains 50% polyurethane material, 25% intrinsic luminescent powder (zinc sulfide), and the remainder is a mixed solvent of butyl acetate, xylene, and trimethylbenzene.

[0098] (5) A transparent conductive paint is sprayed onto the surface of the light-emitting layer, the surface of the sub-line layer, one side of the light-emitting layer and the dielectric layer facing the sub-line layer, and one side of the adjacent spacer region of the sub-line layer to form a uniform transparent conductive layer (thickness of 0.015 mm), thereby obtaining an electroluminescent device. The transparent conductive paint contains 30% conjugated polymer (specifically poly3,4-ethylenedioxythiophene) and the balance is isopropanol;

[0099] (6) Apply conductive adhesive (Zhongshuo Z6011 conductive adhesive) to the busbar layer and sub-line layer respectively, and connect the positive and negative terminals of the controller to the busbar layer and sub-line layer by abutting or sticking to the contacts.

[0100] (7) Spray varnish onto the surface of the paint layer to obtain a varnish layer (thickness of 0.03 mm), wherein the varnish contains 80 wt% epoxy resin and the remainder is a diluent (a mixed solvent of butyl acetate, xylene and trimethylbenzene).

[0101] Example 2

[0102] The electroluminescent device of Example 2 was prepared using a method similar to that of Example 1, except that it also included the following steps:

[0103] (6) Spray paint onto the surface of the transparent conductive layer to form a paint layer (thickness of 0.02 mm), wherein the paint contains wt% epoxy resin, 10wt% abrasive (specifically composed of titanium dioxide), and the remainder is a diluent (a mixed solvent of butyl acetate, xylene, and trimethylbenzene).

[0104] (7) Spray varnish onto the surface of the paint layer to obtain a varnish layer (thickness of 0.03 mm), wherein the varnish contains 80 wt% epoxy resin and the remainder is a diluent (a mixed solvent of butyl acetate, xylene, and trimethylbenzene).

[0105] (8) Apply conductive adhesive (Zhongshuo Z6011 conductive adhesive) to the busbar layer and sub-line layer respectively, and connect the positive and negative terminals of the controller to the busbar layer and sub-line layer by abutting or sticking to the contacts.

[0106] Comparative Example 1

[0107] The electroluminescent device of Comparative Example 1 was manufactured using a method similar to that of Example 1, except that step (2) was not included, and the resulting conductive layer was an integral conductive coating with a surface finish of 8 GU. Then, conductive strips were placed between the light-emitting layer and the transparent electrode layer, and the positive and negative terminals in the controller were connected through the conductive strips.

[0108] Table 1 shows the performance parameters of the electroluminescent devices manufactured in Examples 1-2 and Comparative Example 1.

[0109] Table 1 shows the performance parameters of the electroluminescent device:

[0110] Table 2 shows the production parameters of the electroluminescent devices manufactured in Examples 1-2 and Comparative Example 1.

[0111] Table 2 shows the production parameters for the electroluminescent device:

[0112] As shown in Table 2, the production parameters of Examples 1-2 of the present invention are significantly improved compared to Comparative Example 1.

[0113] It should be noted that all technical features described in this application can be freely combined or combined in any way, unless they contradict each other. Various modifications and variations can be made to this invention without departing from its scope, as will be apparent to those skilled in the art. For example, features shown or described as part of one embodiment can be used with another embodiment to produce yet another embodiment. Therefore, this invention is intended to cover these modifications and variations falling within the scope of the appended claims and their equivalents.

Claims

1. An electroluminescent device, characterized in that, The electroluminescent device includes: Substrate; A conductive layer on the surface of a substrate, the conductive layer comprising a busbar layer and a sub-busbar layer, wherein there is a gap between the busbar layer and the sub-busbar layer; A dielectric layer on the surface of the busbar layer of the conductive layer, a portion of which covers one side of the busbar layer adjacent to the spacer region and covers at least a portion of the spacer region; A light-emitting layer on a dielectric layer; A transparent conductive layer on the light-emitting layer, a portion of which covers one side of the light-emitting layer and the dielectric layer facing the sub-line layer and the side of the sub-line layer adjacent to the spacer region, and covers another portion of the sub-line layer and the spacer region.

2. The electroluminescent device according to claim 1, characterized in that, The dielectric layer covers the entire spacer region, and a portion of the transparent conductive layer covers the light-emitting layer and the dielectric layer on one side of the sub-line layer and covers the sub-line layer.

3. The electroluminescent device according to claim 1, characterized in that, Both the busbar layer and the sub-busbar layer are formed of an oily / grease-based conductive material; Preferably, the oily / grease-based conductive material comprises an adhesive material and metal nanoparticles, wherein the adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material, and the metal nanoparticles comprise copper nanoparticles and / or silver nanoparticles.

4. The electroluminescent device according to claim 1, characterized in that, The dielectric layer is formed of an oily / grease-based dielectric material; Preferably, the oily / grease-based dielectric material comprises an adhesive material and ceramic capacitor nanoparticles, wherein the adhesive material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material, and the ceramic capacitor nanoparticles comprise at least one of barium titanate, lithium barium titanate, zirconium oxide, and lead zirconium titanate.

5. The electroluminescent device according to claim 1, characterized in that, The light-emitting layer is formed of an oily / lipidic light-emitting material; Preferably, the oily / grease-based luminescent material comprises a binder material and an intrinsic luminescent material, wherein the binder material comprises any one or a combination of two or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material, and the intrinsic luminescent material comprises at least one of zinc sulfide, zinc selenide, calcium antimonate, and aluminum 8-hydroxyquinoline.

6. The electroluminescent device according to claim 1, characterized in that, The transparent conductive layer is formed of a water-based transparent conductive material; Preferably, the transparent conductive material comprises a conjugated polymeric conductive polymer and / or carbon nanotubes; wherein the conjugated polymeric conductive polymer comprises at least one of poly(3,4-ethylenedioxythiophene), polyaniline, and polythiophene.

7. The electroluminescent device according to claim 1, characterized in that, The electroluminescent device also satisfies one or more of the following: The thickness of the busbar layer is 0.02–0.04 mm; The thickness of the sub-line layer is 0.02–0.04 mm; The thickness of the busbar layer is the same as the thickness of the sub-busbar layer, both being 0.02–0.04 mm; The length of the gap between the busbar layer and the sub-busbar layer is ≥0.3mm; The surface precision of the busbar layer and the sub-busbar layer is 5-15 GU; The boundary accuracy of the side adjacent to the busbar layer and / or the side adjacent to the sub-busbar layer in the interval area is ≤0.1mm; The thickness of the dielectric layer is 0.02–0.04 mm; The thickness of the light-emitting layer is 0.02–0.04 mm; The thickness of the transparent conductive layer is ≥0.01mm, preferably 0.01~0.015mm; The total thickness of the busbar layer, dielectric layer, light-emitting layer and transparent conductive layer shall not exceed 0.15 mm, preferably 0.07 to 0.135 mm; The electroluminescent device further includes a primer layer between the substrate and the conductive layer, wherein the primer layer comprises epoxy resin and abrasive, and the thickness of the primer layer is 0.02 to 0.04 mm; The electroluminescent device further includes a controller that connects the bus layer and the sub-line layer, and the controller outputs an AC signal; preferably, the positive terminal and the negative terminal in the controller are connected to the bus layer and the sub-line layer by conductive adhesive in a contacting or bonding manner.

8. The electroluminescent device according to claim 1, characterized in that, The electroluminescent device further includes a varnish layer formed on a transparent conductive layer; preferably, the varnish layer is formed of varnish, which is composed of epoxy resin and organic solvent; preferably, the thickness of the varnish layer is 0.02 to 0.06 mm.

9. The electroluminescent device according to claim 1 or 8, characterized in that, The electroluminescent device further includes a colored paint layer formed on a transparent conductive layer or a colored paint layer formed between a transparent conductive layer and a clear varnish layer; preferably, the colored paint layer is formed of epoxy resin and abrasive; the thickness of the colored paint layer is 0.02 to 0.1 mm.

10. The electroluminescent device according to claim 9, characterized in that, The total thickness of the busbar layer, dielectric layer, light-emitting layer, transparent conductive layer, paint layer, and varnish layer shall not exceed 0.35 mm.

11. The electroluminescent device according to any one of claims 1-10, characterized in that, The electroluminescent device has an electrical half-life of more than 2000 hours.

12. A method for manufacturing an electroluminescent device according to any one of claims 1-11, characterized in that, Includes the following steps: (1) Coat the substrate surface with conductive paint to form a conductive layer; (2) Using laser engraving process, a portion of the conductive layer is engraved until the substrate surface is exposed, forming a busbar layer, a sub-busbar layer and a spacer area between the busbar layer and the sub-busbar layer. (3) Apply capacitor paint to the surface of the busbar layer and one side of the adjacent interval area of ​​the busbar layer to form a dielectric layer; (4) Coat the surface of the dielectric layer with luminescent paint to form a luminescent layer; (5) A transparent conductive paint is coated on the surface of the light-emitting layer, the surface of the sub-line layer, the surface of the light-emitting layer and the dielectric layer facing the sub-line layer, and the surface of the sub-line layer adjacent to the spacer region to form a transparent conductive layer, thereby producing an electroluminescent device.

13. The manufacturing method according to claim 12, characterized in that, The manufacturing method also satisfies at least one of the following: The manufacturing method further includes coating a primer layer on the surface of the substrate before step (1), preferably, the primer layer is formed by a primer comprising epoxy resin, abrasive and organic solvent; The conductive paint comprises an organic solvent, an adhesive material, and metal nanoparticles. The adhesive material comprises any one or more of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material. The metal nanoparticles comprise copper nanoparticles and / or silver nanoparticles. The organic solvent comprises at least one of butyl acetate, xylene, and trimethylbenzene. In step (2), the surface accuracy of the bus layer and the sub-line layer is 5-15 GU; the length of the gap between the bus layer and the sub-line layer is ≥0.3 mm; the engraving parameters include: laser power of 30-40 W, scanning speed of 800-1200 mm / s, pulse frequency of 20 kHz-30 kHz, and spot diameter of 80-100 μm; In step (3), the capacitor paint contains an organic solvent, an adhesive material and ceramic capacitor nanopowder. The adhesive material contains any one or more of polyurethane material, epoxy resin and polyester resin, preferably polyurethane material. The ceramic capacitor nanopowder contains at least one of barium titanate, lithium barium titanate, zirconium oxide and lead zirconium titanate. In step (4), the luminescent paint comprises an organic solvent, an adhesive material, and an intrinsic luminescent material. The adhesive material comprises any one or more combinations of polyurethane material, epoxy resin, and polyester resin, preferably polyurethane material. The intrinsic luminescent material comprises at least one of zinc sulfide, zinc selenide, calcium antimonate, and aluminum 8-hydroxyquinoline. The organic solvent comprises at least one of butyl acetate, xylene, and trimethylbenzene. In step (5), the transparent conductive paint contains at least one of carbon nanotubes and a conjugated polymer conductive polymer and a solvent. The solvent contains an organic solvent and / or deionized water. The organic solvent contains at least one of isopropanol and ethanol. The conjugated polymer conductive polymer contains at least one of poly(3,4-ethylenedioxythiophene), polyaniline and polythiophene. The organic solvent contains at least one of butyl acetate, xylene and trimethylbenzene.

14. The manufacturing method according to claim 12, characterized in that, The manufacturing method further includes: Step (6): Coat the surface of the transparent conductive layer with colored paint to form a colored paint layer; and / or coat the surface of the transparent conductive layer with varnish to obtain a varnish layer; Preferably, the manufacturing method further includes step (7): coating a clear varnish onto the surface of the paint layer to obtain a clear varnish layer; More preferably, the paint comprises epoxy resin, mortar, and organic solvent; More preferably, the varnish is formed from epoxy resin and organic solvent.

15. The manufacturing method according to any one of claims 12-14, characterized in that, The manufacturing method further includes: controller installation: attaching contacts to the busbar layer and sub-busbar layer respectively with conductive adhesive, and connecting the positive and negative terminals of the controller to the busbar layer and sub-busbar layer by abutting or attaching to the contacts.

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