Coatable Conductive Layer for Patterned Displays
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Solution Overview
Problem
Current display technologies using polymer-dispersed cholesteric liquid crystals require vacuum coatings and intricate printing processes, which are expensive, fragile, and environmentally harmful, lacking a fast and dry patterning method for conductive layers.
Innovation Solution
A patternable coatable electrically conductive layer is developed using a fluid-coated conductive material with sufficient conductivity to induce an electric field, allowing for the creation of a display with a light modulating layer, where the conductive layer is formed by coating a substrate with a fluid containing fine conductive particles and a binding agent, and patterned using actinic radiation, eliminating the need for vacuum deposition and printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum deposition is used to create conductive layers, then the conductive layer has good electrical conductivity, but the process becomes expensive and fragile
Solution Approach 1:
The patent replaces vacuum deposition (a complex mechanical/physical vapor deposition process) with a chemical solution-based coating process. The conductive material is applied as a liquid coating that dries to form the conductive layer, eliminating the need for expensive vacuum equipment and complex deposition controls while maintaining electrical conductivity and improving layer durability.
Solution Approach 2:
The patent changes the physical state of the conductive material from vapor (in vacuum deposition) to liquid solution form. This parameter change allows the conductive material to be applied through simple coating and drying processes rather than requiring vacuum deposition equipment, thereby simplifying manufacturing while producing more durable conductive layers.
2Manufacturing precision
If printing processes are used to pattern conductive layers, then precise patterns can be achieved, but the process becomes slow and complex
Solution Approach 1:
The patent replaces mechanical printing processes with a chemical etching process. The conductive coating is first applied uniformly across the substrate, then patterned by selectively removing material through chemical etching. This substitution eliminates the mechanical complexity of printing while achieving precise patterns and significantly increasing production speed.
Solution Approach 2:
The patent applies the conductive coating uniformly across the entire substrate before patterning. This preliminary uniform coating simplifies the subsequent patterning step, as the material is already in place and only requires selective removal rather than precise placement. This approach increases productivity while maintaining pattern accuracy through the etching process.
3Ease of manufacture
If conventional conductive inks are used, then conductive layers can be formed, but harmful chemicals and polymeric binders are required
Solution Approach 1:
The patent uses a water-based coating system that eliminates the need for harmful organic solvents and polymeric binders. The coating is applied and then dried, leaving a clean conductive layer without requiring chemical etchants or harmful processing steps. This approach maintains manufacturing simplicity while eliminating environmental harm from toxic chemicals.
Solution Approach 2:
The patent converts the potential harm of using complex conductive inks into benefit by using a simplified water-based system. Instead of dealing with harmful polymeric binders and organic solvents, the invention uses a clean coating process that dries to form the conductive layer, turning a potentially harmful process into an environmentally friendly one while maintaining ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution eliminates the need for vacuum deposited conductors and printing machinery, providing a cost-effective, environmentally friendly, and efficient method for creating patterned conductive layers in displays, enabling fast and dry patterning while maintaining the optical properties of polymer-dispersed cholesteric liquid crystals.
Implementation Method 1
the electrically conductive material has sufficient conductivity to induce an electric field strong enough to change the optical state of a light modulating material
Implementation Method 2
patterned using actinic radiation
Data Source
AI summary
The invention relates to a patternable coatable electrically conductive layer comprising a fluid-coated electrically conductive material, wherein the fluid-coated electrically conductive material has sufficient conductivity to induce an electric field strong enough to change the optical state of a light modulating material and a display comprising a substrate, at least one patternable coatable electrically conductive layer comprising a fluid-coated electrically conductive material, wherein said fluid coated electrically conductive material has sufficient conductivity to induce an electric field strong enough to change the optical state of a light modulating material which has a first and a second field-switched stable optical state, and an imaging layer comprising said light modulating material disposed over said at least one patternable fluid-coated electrically conductive layer. The invention also relates to a method for making a coatable electrically conductive layer and a method for making a display with a coatable electrically conductive layer.