Laminated Electro-Optic Display Interconnects Without Precision Alignment
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Solution Overview
Problem
The existing manufacturing processes for laminated electro-optic displays, particularly large and custom displays, face challenges in precise alignment and cost-effectiveness due to the need for stringent alignment of the front plane laminate and backplane, limiting the use of mass production techniques like roll-to-roll coating.
Innovation Solution
A method involving a backplane with a scored cut-out or hole for the conductor, allowing for a non-precision lamination process that exposes the top conducting layer after lamination, enabling a conductive filler to create a reliable electrical connection without precise alignment, suitable for large and custom displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise alignment methods are used for laminating front plane laminate and backplane, then manufacturing precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention divides the electrical connection function into two separate stages: (1) mechanical lamination without alignment requirements, and (2) subsequent formation of conductive pathways through the laminate. This segmentation allows the lamination process itself to be simple and low-cost, while the electrical connection is achieved through a separate conductive material application process.
Solution Approach 2:
The invention performs preliminary lamination without alignment requirements, accepting that electrical connections are not yet established. The alignment and electrical connection are then achieved in a subsequent step by applying conductive material to predetermined locations, separating the mechanical bonding function from the electrical connection function.
2Manufacturing precision
If precise alignment methods are used for laminating front plane laminate and backplane, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The manufacturing process is segmented into independent steps: rapid lamination without alignment, followed by conductive material application. This eliminates the time-consuming alignment step from the critical path, significantly improving manufacturing speed while maintaining electrical connection integrity through the subsequent conductive material step.
Solution Approach 2:
The lamination is performed as a preliminary action without waiting for alignment to be achieved. The front plane laminate is laminated to the backplane first, and electrical connections are established afterward through conductive material application, allowing parallel processing and improved throughput.
3Ease of manufacture
If non-precision lamination is used, then ease of manufacture is improved, but reliability of electrical connection deteriorates
Solution Approach 1:
The invention introduces conductive material as an intermediary substance that bridges the electrical connection between the front plane laminate and backplane. This mediator compensates for the lack of precise alignment by providing a compliant conductive pathway that can accommodate positioning tolerances while ensuring reliable electrical connection.
Solution Approach 2:
The invention changes the approach to electrical connection from rigid mechanical alignment to a more compliant method using conductive material with adjustable properties (viscosity, conductivity, particle size). This parameter change allows the system to tolerate larger positioning variations while maintaining reliable electrical connections.
Data Source
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AI summary
A laminated electro-optic display is provided, comprising: front transparent substrate; a rear substrate having a plurality of conductors; and a plurality of layers between the front substrate and the rear substrate. The plurality of layers comprises a layer of electro-optic media, a first conductive layer positioned between the front substrate and the electro-optic media, and a second conductive layer positioned between the electro-optic media and the rear substrate. The rear substrate includes a through-hole filled with a conductive material such that at least one of the plurality of conductors is electrically connected via the conductive material to the first conductive layer.