Luminescent Composition Screen Printing for Mass Production
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Solution Overview
Problem
Existing electroluminescent sheet production methods are costly and unsuitable for mass production due to the need for expensive equipment and complex procedures, limiting their productivity and efficiency for applications like advertising media and security sheets.
Innovation Solution
A luminescent composition with pressure-sensitive adhesive properties is developed by dispersing electroluminescent substances in a resin with a specific glass transition temperature, allowing for the efficient production of electroluminescent sheets through a simplified laminate bonding process, enabling high productivity and low costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (sintering, laser abrasion, MBE, PVD, CVD) are used to form the electroluminescent layer, then the electroluminescent sheet can be produced with good quality, but the production cost increases and the process becomes complex, making mass production difficult
Solution Approach 1:
The patent replaces complex physical vapor deposition methods (PVD, CVD, sintering) with a simple screen printing technique. The electroluminescent material is dispersed in a binder and applied through screen printing, eliminating the need for expensive vacuum deposition equipment and complex multi-step processes while maintaining layer quality
Solution Approach 2:
The patent uses a disposable screen printing stencil instead of expensive, complex deposition equipment. The screen printing approach allows for low-cost mass production by replacing capital-intensive machinery with a simple, reusable screen template that can be easily discarded or replaced
2Manufacturing precision
If conventional methods (sintering, laser abrasion, MBE, PVD, CVD) are used to form the electroluminescent layer, then the electroluminescent sheet can be produced with good quality, but the production time increases and productivity decreases
Solution Approach 1:
The patent replaces time-consuming physical vapor deposition processes with rapid screen printing. The screen printing method allows for quick application of the electroluminescent layer in a single step, dramatically reducing production time and enabling high-volume manufacturing while maintaining layer uniformity and quality
Solution Approach 2:
The electroluminescent material is pre-dispersed in the binder to form a ready-to-print paste before screen printing. This preliminary preparation eliminates the need for complex in-situ material deposition during production, allowing for rapid application and significantly improving manufacturing speed
3Reliability
If expensive equipment and complicated procedures are used, then the electroluminescent layer can be formed with good properties, but the production cost becomes very high, making mass production unsuitable
Solution Approach 1:
The patent replaces expensive physical vapor deposition equipment with simple screen printing technology. The electroluminescent layer is applied using a straightforward screen printing process that requires minimal equipment investment, dramatically reducing manufacturing costs while maintaining layer reliability through proper material formulation and printing technique
Solution Approach 2:
The patent uses a composite material system where electroluminescent particles are dispersed in a binder matrix. This composite approach allows for cost-effective mass production by using readily available materials instead of expensive pure substances, while the composite structure maintains layer stability and functional properties
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
The approach enables the mass production of electroluminescent sheets with high luminance and efficiency, suitable for advertising and security applications, while reducing production costs and complexity.
Implementation Method 1
a luminescent composition having a pressure sensitive adhesive property and produced by kneading and dispersing an electroluminescent substance in a resin having a glass transition temperature of from -70 to 5°C
Data Source
Figure 1~4
AI summary
The present invention provides a luminescent composition capable of providing an electroluminescent sheet with a high productivity at low costs in an efficient manner, an electroluminescent sheet obtained from the luminescent composition which can be mass-produced, and a process for producing the electroluminescent sheet. The present invention relates to an adhesive luminescent composition produced by kneading and dispersing an electroluminescent substance in a resin having a glass transition temperature of from -70 to 5°C; an electroluminescent sheet including at least a first substrate, a first electrode, an electroluminescent layer, a second electrode and a second substrate which are successively laminated in this order, wherein the first substrate and the first electrode are transparent, and the electroluminescent layer is formed from the luminescent composition; and a process for producing the electroluminescent sheet, including the steps of preparing a first laminate and a second laminate by the following step (1) or (2); and bonding a side of the electroluminescent layer of the first laminate to a side of the second electrode of the second laminate, or bonding a side of the first electrode of the first laminate to a side of the electroluminescent layer of the second laminate: Step (1): successively forming at least the first electrode and the electroluminescent layer on the first substrate to prepare the first laminate, and separately forming at least the second electrode on the second substrate to prepare the second laminate; or Step (2): forming at least the first electrode on the first substrate to prepare the first laminate, and separately successively forming at least the second electrode and the electroluminescent layer on the second substrate to prepare the second laminate.