Continuous Extruded Fiber Ribbons for Wide Laser Phosphor Displays
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Solution Overview
Problem
Current methods for producing image panels for laser-phosphor displays are limited by precision printing processes that require multiple steps, precision alignment, and are restricted in width and length, leading to inefficiencies in fabricating large displays.
Innovation Solution
A method involving extrusion of individual fibers with core and ink portions to create micro-ribbons, which are then bonded with light blocking fibers to form color stripes, allowing for continuous production of wide aspect ratio phosphor stripes in a seamless process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision printing process is used to produce image panels, then manufacturing precision can be maintained, but device complexity and loss of time increase due to multiple steps including joining sheets, alignment, trimming, and seaming
Solution Approach 1:
The patent combines multiple discrete printing steps into a single continuous extrusion process that produces phosphor ribbons directly in the desired final configuration. The extrusion process simultaneously creates multiple color ribbons with proper spacing and alignment, eliminating the need for separate printing, joining, and alignment operations.
Solution Approach 2:
The patent implements a continuous extrusion process that produces phosphor ribbons without interruption, replacing the discrete step-by-step printing process. The continuous extrusion allows for uninterrupted production of large-area displays, eliminating the need to stop and join multiple sheets together.
2Manufacturing precision
If precision printing process is used to produce large image panels, then manufacturing precision can be maintained, but productivity decreases due to multiple steps and size limitations
Solution Approach 1:
The patent segments the phosphor structure into distinct continuous ribbons of different colors that are extruded simultaneously. Each ribbon maintains its own integrity while being produced in a continuous process, allowing for precise registration without the need to join discrete printed sheets.
Solution Approach 2:
The continuous extrusion process produces phosphor ribbons without interruption, enabling the fabrication of large-area displays in a single continuous operation. This eliminates the need to stop production for joining sheets, significantly improving productivity while maintaining precision through the inherent stability of the extrusion process.
3Area of stationary object
If multiple sheets are joined to produce large image panels, then area coverage can be increased, but loss of time increases due to joining, alignment, and seaming operations
Solution Approach 1:
The continuous extrusion process produces phosphor ribbons that can extend to any required length without interruption. This allows for the creation of large-area displays in a single continuous fabrication run, eliminating the time-consuming operations of joining, aligning, and sealing multiple separate sheets together.
4Manufacturing precision
If precision trimming and seaming are performed to produce final display format, then manufacturing precision is maintained, but device complexity and loss of time increase
Solution Approach 1:
The extrusion process is configured to produce phosphor ribbons with the exact final dimensions and spacing required for the display format. By pre-establishing the correct ribbon widths, spacing, and lengths during extrusion, the need for subsequent trimming and seaming operations is eliminated.
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 approach enables efficient and effective fabrication of large image panels with improved registration and reduced seaming, producing continuous rolls of RGB sheets for displays.
Implementation Method 1
Individual fibers are made using an extrusion process whereby a core surrounded by an ink portion is extruded to create an individual fiber
Implementation Method 2
The individual fibers are then bonded to adjacent fibers to create micro-ribbon structures
Data Source
AI summary
The present disclosure generally relates to micro-ribbon structures used in display systems and methods of fabrication thereof. Individual fibers are made using an extrusion process whereby a core surrounded by an ink portion is extruded to create an individual fiber. The ink portion may include both an inner portion that is in contact with the core and an outer shell portion over the inner portion. The individual fibers are then bonded to adjacent fibers to create micro-ribbon structures. The micro-ribbon structures are of one color and spaced from adjacent micro-ribbon structures of a different color by a light blocking fiber. The micro-ribbon structures are each bonded to the light blocking fiber to create the color stripes used in the display system.