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WO2005062679A1 - Flexible front electrode films and electro-luminescence devices using the same - Google Patents

Flexible front electrode films and electro-luminescence devices using the same Download PDF

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Publication number
WO2005062679A1
WO2005062679A1 PCT/KR2004/003372 KR2004003372W WO2005062679A1 WO 2005062679 A1 WO2005062679 A1 WO 2005062679A1 KR 2004003372 W KR2004003372 W KR 2004003372W WO 2005062679 A1 WO2005062679 A1 WO 2005062679A1
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WO
WIPO (PCT)
Prior art keywords
front electrode
electrode layer
layer
mesh type
flexible front
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/KR2004/003372
Other languages
French (fr)
Inventor
Jang Hwan Bae
Shin Kim
Hui Kwan Shin
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GA KOREA TECH Co Ltd
Original Assignee
GA KOREA TECH Co Ltd
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Filing date
Publication date
Application filed by GA KOREA TECH Co Ltd filed Critical GA KOREA TECH Co Ltd
Publication of WO2005062679A1 publication Critical patent/WO2005062679A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/12—Light sources with substantially two-dimensional radiating surfaces
    • H05B33/26—Light sources with substantially two-dimensional radiating surfaces characterised by the composition or arrangement of the conductive material used as an electrode
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/12—Light sources with substantially two-dimensional radiating surfaces
    • H05B33/26—Light sources with substantially two-dimensional radiating surfaces characterised by the composition or arrangement of the conductive material used as an electrode
    • H05B33/28—Light sources with substantially two-dimensional radiating surfaces characterised by the composition or arrangement of the conductive material used as an electrode of translucent electrodes
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K2102/00—Constructional details relating to the organic devices covered by this subclass
    • H10K2102/301—Details of OLEDs
    • H10K2102/311—Flexible OLED
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
    • H10K77/10—Substrates, e.g. flexible substrates
    • H10K77/111—Flexible substrates

Definitions

  • the present invention relates, in general, to flexible front electrode films and electro-luminescent devices using the same.
  • the present invention relates to a flexible front electrode film composed of a flexible transparent polymer film and a front electrode layer formed to a predetermined thickness on the transparent polymer film by printing a conductive material in a mesh pattern on the transparent polymer film; and an electro-luminescent device comprising such a flexible front electrode film, and a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, sequentially printed on the flexible front electrode film.
  • an electro-luminescent device is composed of an ITO (Indium Tin Oxide) film having a transparent front electrode layer formed by applying ITO on an entire surface of a transparent film having a predetermined thickness, and a luminescent layer, an insulating layer and a rear electrode layer, each of which has a predetermined thickness, sequentially formed on the ITO film.
  • ITO Indium Tin Oxide
  • a predetermined alternating voltage is applied to the transparent front electrode layer and the rear electrode layer, light generated by the luminescent layer is wholly radiated through the transparent front electrode layer.
  • the ITO film used in the conventional electro-luminescent device is composed of. the front electrode layer including inflexible glass or a relatively rigid transparent polyester film coated with ITO as a conductive material by means of sputtering, it has low flexibility, tensile strength and elastic strength. Hence, when tension is applied throughout the device while the device is used for exterior signboards, the device cannot resist the tension. Further, the conventional electro-luminescent device, which is manufactured using the ITO film having drastically low flexibility, tensile strength and elastic strength, has the following problems. That is, first, since the conventional electro-luminescent device cannot be wound in a roll, it cannot be manufactured to have a large area.
  • the conventional electro-luminescent device is formed using an expensive ITO film, high manufacturing costs are incurred.
  • the conventional electroluminescent device is manufactured in batches, it has a limited size. Therefore, an electro-luminescent device having a large area cannot be continuously manufactured on a large scale.
  • the conventional electroluminescent device is manufactured at a size of 1 m 2 or less and has low flexibility, tensile strength and elastic strength, it has only been used for small decorative luminescent plates or interior small signboards. If it is used for larger exterior signboards, it may be discolored or decolored by ultraviolet rays. Thus, the conventional electro-luminescent device cannot fulfill various demands of consumers .
  • an object of the present invention is to provide a novel flexible front electrode film, which has high flexibility, tensile strength and elastic strength so that it is able to be wound in a roll.
  • Another object of the present invention is to provide an electro-luminescent device having a large area, which is able to be wound in a roll by sequentially printing a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, on a flexible front electrode film able to be wound in a roll.
  • a further object of the present invention is to provide a flexible front electrode film, which comprises a transparent polymer film having flexibility, tensile strength and elastic strength and a front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film to form a plurality of transmission parts, in which the conductive material is not damaged or detached when the " film is wound in a roll.
  • Yet another object of the present invention is to provide a flexible front electrode film able to be wound in a roll, which comprises a transparent polymer film having flexibility, tensile strength and elastic strength while blocking ultraviolet rays and a front electrode layer formed to a predetermined thickness on the polymer film by attaching a conductive synthetic fiber mesh sheet on the polymer film to form a plurality of transmission parts .
  • Still another object of the present invention is to provide an electro-luminescent device having a large area for use in exterior signboards, which is manufactured by means of gravure printing or the like in such a way that a flexible front electrode film, which is wound in a roll, is continuously passed through between a plurality of rollers to sequentially form a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, on the flexible front electrode film.
  • a flexible front electrode film comprises a transparent polymer film, having flexibility, tensile strength and elastic strength while blocking ultraviolet rays, and a front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film or by attaching a conductive fiber mesh sheet on the polymer film to form a plurality of transmission parts.
  • An electro-luminescent device of the present invention can be wound in a roll, by sequentially applying a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, throughout a flexible front electrode film having a plurality of transmission parts. Since the flexible front electrode film of the present invention can be wound in a roll, the electro- luminescent device having a large area can be manufactured on a large scale in such a way that the flexible front electrode film is continuously passed through between a plurality of rollers, thus fulfilling various demands of consumers .
  • the electro-luminescent device of the present invention can be wound in a roll, it incurs low storing and transporting expenses, and can be easily used for various curved surfaces, and thus, it can serve as a self-luminescent film for exterior signboards having large areas.
  • FIG. 1 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a first embodiment of the present invention
  • FIG. 2 is a schematic perspective view showing a mesh type front electrode layer, according to the first embodiment of the present invention
  • FIG. 3 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a second embodiment of the present invention
  • FIG. 4 is a schematic perspective view showing a mesh type front electrode layer, according to the second embodiment of the present invention
  • FIG. 5 is a partially enlarged perspective view showing a conductive synthetic resin sheet usable in the mesh type front electrode layer shown in FIG. 4;
  • FIG. 6 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a third embodiment of the present invention
  • FIG. 7 is a schematic sectional view showing the action of the electro-luminescent device using the flexible front electrode film, according to the present invention.
  • a flexible front electrode film comprises a transparent polymer film having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays, and a mesh type front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film to regularly form a plurality of transmission parts having predetermined shapes.
  • the opaque conductive material of the mesh type front electrode layer is a conductive polymer or a conductive metal paste.
  • the opaque conductive material includes a polymer binder to manifest flexibility and elasticity.
  • the transmission part of the mesh type front electrode layer is filled with a transparent conductive material.
  • the transparent conductive material is an ITO paste including a polymer binder.
  • the transmission part of the flexible front electrode film constitutes 60% or more of the total area thereof.
  • the width of the transmission part is 1-10 mm.
  • a flexible front electrode film of the present invention comprises a transparent polymer film having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays, and a mesh type front electrode layer formed on the polymer film by attaching a conductive synthetic fiber sheet woven in a mesh pattern on the polymer film to regularly form a plurality of transmission parts having predetermined shapes .
  • the conductive synthetic fiber sheet comprises a synthetic yarn having tensile strength and elastic strength and a conductive metal ion incorporated in or applied on the synthetic yarn.
  • an electro-luminescent device of the present invention comprises the flexible front electrode film, a luminescent layer having a predetermined thickness applied throughout the flexible front electrode film, an insulating layer having a predetermined thickness applied throughout the luminescent layer, a rear electrode layer having a predetermined thickness applied throughout the insulating layer, and a protective layer being resistant to moisture and ultraviolet rays and having a predetermined thickness applied on the rear electrode layer.
  • the electro-luminescent device is continuously manufactured in a roll, and thus, is usable for exterior signboards having large areas.
  • the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a mesh type front electrode layer 14 formed on the polymer film by printing a conductive material in a mesh pattern on the polymer film to form a plurality of transmission parts 15.
  • a luminescent layer 16 an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially applied.
  • the mesh type front electrode layer 14 and the rear electrode layer 18 are connected with electrodes to which a predetermined alternating voltage is applied, so that light generated by the luminescent layer 16 is externally radiated through the plurality of transmission parts ,15. Since the electro-luminescent device- 10 is composed of the conductive material 24 having flexibility and elasticity printed in a mesh pattern on the flexible transparent polymer film 13 to form the plurality of transmission parts 15, even if it is wound in a roll, the front electrode layer is not damaged or detached.
  • the transparent polymer film 13 is formed of a polymer material having flexibility to the extent that it may be wound in a roll, and has tensile strength and elastic strength to the extent that it is not torn or deformed when manufactured to have a large area.
  • the transparent polymer film 13 should be transparent so that light radiated from the luminescent layer 16 can be sufficiently transmitted.
  • the transparent polymer film 13 is formed of a synthetic resin selected from among PVC (Polyvinyl Chloride) , PET (Polyethylene Terephthalate) , and PMMA (Polymethyl methacrylate) , and has a thickness of about 50 ⁇ m or more.
  • the transparent polymer film 13 functions as a base substrate on which the plurality of coating layers including the mesh type front electrode layer 14 are sequentially applied, and also serves as a protective film for protecting the inner coating layers when being used for exterior signboards.
  • the transparent polymer film 13 should have tensile strength and elastic strength to fulfill such functions and conditions.
  • the above polymer film may be integrated with a synthetic fiber mesh sheet which is not shown, to increase the tensile strength and elastic strength, if required.
  • the above polymer film has an additive that blocks ultraviolet rays.
  • the mesh type front electrode layer 14 formed on the transparent polymer film 13 comprises the conductive material 24 printed in a mesh pattern, as shown in FIG. 3.
  • the mesh type front electrode layer 14 including the conductive material 24 printed in a mesh pattern is structured so that a plurality of wires 241, each of which has predetermined width and thickness, are cross-linked to each other.
  • inner spaces defined by the. cross-linked wires 241 are provided as rectangular transmission parts 15.
  • the conductive material 24 is a conductive polymer or a conductive metal paste having viscosity suitable for printing.
  • the conductive polymer is selected from among polyacethylene, polypyrrole, polythiophene, poly-biphenylene, N-methylphenolthiazine and polyphenothiazine .
  • the conductive metal paste includes conductive metal powder made of copper, aluminum or silver mixed to a polymer binder.
  • the mesh type front electrode layer 14 is formed by printing the conductive material 24 throughout the transparent polymer film 13 using a screen printing process or a gravure printing process.
  • screen printing the transparent polymer film 13 is mounted to a screen printer, after which the conductive material 24 applied on a mesh screen is printed using a squeegee to form a mesh type front electrode layer 14.
  • the transparent polymer film 13 wound in a roll is passed through between a plurality of printing rollers having a mesh pattern and corresponding pressing rollers, to form a mesh type front electrode layer 14.
  • the printing roller which is supplied with the conductive material 24 from a conductive material source while being rotated at a predetermined speed on its axis, continuously prints the conductive material 24 on the transparent polymer film 13 to obtain the mesh type front electrode layer 14.
  • the printed conductive material is securely adhered to the transparent polymer film 13 through heat treatment.
  • the conductive material 24 of the mesh type front electrode layer 14 includes a certain polymer binder so as to retain flexibility and elasticity even after being dried.
  • the transmission part 15 of the mesh type front electrode layer 14 is not limited to the shown shape, and may be formed in circular-, pentagonal-, circular-shapes, etc., so long as it fulfills desired transmittance and surface resistance.
  • the wire 141 of the mesh type front electrode layer 14 has a width of 1-5 mm and a thickness of 5-30 ⁇ m, preferably 10-20 ⁇ m. If the mesh type front electrode layer 14 is too thick, flexibility and elasticity are lowered. Conversely, if the above layer is too thin, surface resistance becomes high.
  • the transmission part 15 defined by the cross-linked wires 141 has a width of 1-10 mm. That is, the mesh type front electrode layer 14 is structured so that light generated by the luminescent layer 16 is externally radiated through the transmission part 15. To retain sufficient luminance, the area of the transmission part 15 should be as large as possible.
  • the transmission part 15 preferably constitutes 60-70% of the total area of the mesh type front electrode layer 14.
  • the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a conductive synthetic fiber mesh sheet 35 formed on the polymer film by attaching a conductive synthetic fiber mesh sheet 35 on the polymer film to form a plurality of transmission parts 15.
  • a luminescent layer 16 on the entire surface of the flexible front electrode film 12, a luminescent layer 16, an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially formed.
  • FIG. 4 is a perspective view showing the flexible front electrode film 12 formed by attaching the synthetic fiber mesh sheet 35 on the transparent polymer film 13.
  • the synthetic fiber mesh sheet 35 is composed of a conductive fiber woven in a lattice form.
  • the mesh type front electrode layer 14 includes a plurality of cross-linked wires 341 and rectangular transmission parts 15 defined by the cross-linked wires 341.
  • the conductive fiber is exemplified by a metal fiber, a carbon fiber, a fiber formed of synthetic resin incorporated with metal ion, a plated synthetic fiber, etc., in which the fiber formed of synthetic resin incorporated with metal ion is prepared by incorporating a copper ion in an acryl fiber and then reducing it.
  • FIG. 5 is a schematic perspective view showing the synthetic fiber mesh sheet 35, according to the second embodiment of the present invention.
  • the synthetic fiber mesh sheet 35 is composed of polyester yarns 351 woven at predetermined intervals, a conductive metal 353 having a predetermined thickness applied on the yarn 351, and black carbon 354 applied on the surface of the conductive metal 353 to protect the conductive metal 353.
  • the conductive metal 353 is selected from among copper, silver, aluminum, etc.
  • the yarn 351 is polyester having high tensile strength and elastic strength.
  • the yarn 351 is preferably woven at a density of 80 numbers/inch 2 or more to ensure sufficiently high tensile strength and elastic strength and decrease surface resistance.
  • FIG. 6 is a schematic sectional view showing an electro-luminescent device 10 according to a third embodiment of the present invention.
  • the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a mesh type front electrode layer 14 formed on the polymer film to provide a plurality of transmission parts 15 on which a transparent conductive material 25 is applied to fill the transmission parts 15 with the transparent conductive material 25. Further, a luminescent layer 16, an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially formed on the entire surface of the flexible front electrode film 12.
  • the mesh type front electrode layer 14 is formed by printing the conductive material 24 in a mesh pattern on the transparent polymer film 13 or by attaching a certain synthetic fiber mesh sheet 35 on the transparent polymer film 13.
  • the transparent conductive material 25 is formed of an ITO paste having a viscosity of 10,000-100,000 cps and 10-80 wt% solid content.
  • the ITO paste is composed of ITO powder having low resistance mixed with a high-boiling- point solvent having a predetermined amount of molten resin. For example, 70 g of butyl carbitol acetate is mixed with 20 g of terpineol to form a mixture, in which 10 g of ethyl cellulose is then dissolved while being heated, to obtain a desired solvent.
  • the transparent conductive material 25 is not applied thicker than the front electrode layer 14 so as to ensure flexibility to the extent of being able to be wound in a roll.
  • the transparent conductive material 25 has preferably 50-90% transparency so that light generated by the luminescent layer 16 is sufficiently transmitted.
  • the electro-luminescent device 10 of the present invention is manufactured by sequentially printing -the luminescent layer 16, the insulating layer 17, the rear electrode layer 18 and the protective layer 19, each of which has a predetermined thickness, throughout the flexible front electrode film 12 having the plurality of transmission parts.
  • the electro-luminescent device 10 is preferably manufactured using the gravure printing process in such a way that the flexible front electrode film 12, which is wound in a roll, is continuously passed through between a plurality of printing rollers and corresponding pressing rollers (not shown) to sequentially form the above luminescent layer 16, the insulating layer 17, the rear electrode layer 18 and the protective layer 19 on the flexible front electrode film 12.
  • the luminescent layer 16 is formed in such a way that the flexible front electrode film 12 is passed through between a plurality of rollers to be printed with a luminescent material (ZnS:Mn,Cl) having various activators and earth element impurities acting as a luminescent core added to ZnS powder or ZnF 2 powder including a polymer binder therethroughout, and the printed material is dried at 100-140°C.
  • the luminescent layer 16 has a thickness of 20-50 ⁇ m, and preferably 30-40 ⁇ m.
  • the insulating layer 17 is formed in such a way that the luminescent layer 16 is passed through between a plurality of rollers to be printed with a mixture of insulating powder (BaTi0 3 ) and a cyano resin based polymer binder (MNA) therethroughout, and the printed mixture is dried at 100-150°C.
  • the insulating layer 17 has a thickness of 5-30 ⁇ m, and preferably 15-30 ⁇ m.
  • the rear electrode layer 18 is formed in such a way that the insulating layer 17 is passed through between a plurality of rollers to be printed with a conductive metal paste made of conductive metal powder, such as carbon, copper, silver or aluminum, mixed to the binder therethroughout.
  • the rear electrode layer 18 has light reflectiveness of 80% or more.
  • the rear electrode layer 18 has a thickness of 5-20 ⁇ m.
  • an oxidation protective layer made of platinum, gold, silver or carbon be additionally formed between the rear electrode layer 18 and the protective layer 19.
  • the protective layer 19 having a predetermined thickness and formed of a synthetic resin having high moisture resistance and blocking ultraviolet rays, is provided.
  • the protective layer 19 having high moisture resistance is formed in such a way that the rear electrode layer 18 is passed through between a plurality of rollers to be printed with a molten synthetic resin therethroughout.
  • the protective layer 19 has a thickness of 20-40 ⁇ m.
  • the mesh type front electrode layer 14 and the rear electrode layer 18 are connected with electrodes (bus bars) having predetermined widths which are not shown.
  • the electrodes are formed of copper, silver or aluminum.
  • FIG. 7 the action of the electroluminescent device 10 is shown.
  • the electro-luminescent device 10 manufactured in a roll is used in various sizes and forms.
  • a predetermined alternating voltage is applied to the electrodes which are connected to the mesh type front electrode layer 14 and the rear electrode layer 18
  • light emitted from the luminescent layer 16 is externally radiated through the transmission parts of the mesh type front electrode layer 14.
  • a part of light emitted from the luminescent layer 16 is directed toward the rear electrode layer 18, and then reflected from the rear electrode layer 18.
  • the transmission part 15 of the mesh type front electrode layer 14 constitutes 60-70% of the total area thereof.
  • the front electrode 141 of the mesh type front electrode layer 14 are uniformly distributed to constitute 30-40% of the total area thereof.
  • the mesh type front electrode layer 14 can manifest sufficiently high conductivity.
  • the electroluminescent device 10 of the present invention can be wound on a roll having a diameter of 200-300 mm, since it includes the transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength and the mesh type front electrode layer 14 having flexibility and elastic strength formed thereon.

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  • Electroluminescent Light Sources (AREA)
  • Illuminated Signs And Luminous Advertising (AREA)

Abstract

Disclosed is a flexible front electrode film and an electro-luminescent device using the same. More specifically, a flexible front film (12) includes a flexible transparent polymer film (13) and a mesh type front electrode layer (14) formed to a predetermined thickness on the transparent polymer film by printing a conductive material in a mesh pattern on the transparent polymer film, and an electro-luminescent device (10) includes the flexible front electrode film (12), and a luminescent layer (16), an insulating layer (17), a rear electrode layer (18) and a protective layer (19), each of which has a predetermined thickness, sequentially printed on the flexible front electrode film (12).

Description

[DESCRIPTION]
[invention Title] FLEXIBLE FRONT ELECTRODE FILMS AND ELECTROLUMINESCENCE DEVICES USING THE SAME [Technical Field] The present invention relates, in general, to flexible front electrode films and electro-luminescent devices using the same. More particularly, the present invention relates to a flexible front electrode film composed of a flexible transparent polymer film and a front electrode layer formed to a predetermined thickness on the transparent polymer film by printing a conductive material in a mesh pattern on the transparent polymer film; and an electro-luminescent device comprising such a flexible front electrode film, and a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, sequentially printed on the flexible front electrode film.
[Background Art] Generally, an electro-luminescent device is composed of an ITO (Indium Tin Oxide) film having a transparent front electrode layer formed by applying ITO on an entire surface of a transparent film having a predetermined thickness, and a luminescent layer, an insulating layer and a rear electrode layer, each of which has a predetermined thickness, sequentially formed on the ITO film. When a predetermined alternating voltage is applied to the transparent front electrode layer and the rear electrode layer, light generated by the luminescent layer is wholly radiated through the transparent front electrode layer. Thus, the electro-luminescent device is receiving attention for use in various displays, because it is thin and has a fast response speed and high luminance and is easily manufactured. However, since the ITO film used in the conventional electro-luminescent device is composed of. the front electrode layer including inflexible glass or a relatively rigid transparent polyester film coated with ITO as a conductive material by means of sputtering, it has low flexibility, tensile strength and elastic strength. Hence, when tension is applied throughout the device while the device is used for exterior signboards, the device cannot resist the tension. Further, the conventional electro-luminescent device, which is manufactured using the ITO film having drastically low flexibility, tensile strength and elastic strength, has the following problems. That is, first, since the conventional electro-luminescent device cannot be wound in a roll, it cannot be manufactured to have a large area. Second, since the conventional electro-luminescent device is formed using an expensive ITO film, high manufacturing costs are incurred. Third, since the conventional electroluminescent device is manufactured in batches, it has a limited size. Therefore, an electro-luminescent device having a large area cannot be continuously manufactured on a large scale. Fourth, since the conventional electroluminescent device is manufactured at a size of 1 m2 or less and has low flexibility, tensile strength and elastic strength, it has only been used for small decorative luminescent plates or interior small signboards. If it is used for larger exterior signboards, it may be discolored or decolored by ultraviolet rays. Thus, the conventional electro-luminescent device cannot fulfill various demands of consumers . [Disclosure] [Technical Problem] Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and an object of the present invention is to provide a novel flexible front electrode film, which has high flexibility, tensile strength and elastic strength so that it is able to be wound in a roll. Another object of the present invention is to provide an electro-luminescent device having a large area, which is able to be wound in a roll by sequentially printing a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, on a flexible front electrode film able to be wound in a roll. A further object of the present invention is to provide a flexible front electrode film, which comprises a transparent polymer film having flexibility, tensile strength and elastic strength and a front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film to form a plurality of transmission parts, in which the conductive material is not damaged or detached when the" film is wound in a roll. Yet another object of the present invention is to provide a flexible front electrode film able to be wound in a roll, which comprises a transparent polymer film having flexibility, tensile strength and elastic strength while blocking ultraviolet rays and a front electrode layer formed to a predetermined thickness on the polymer film by attaching a conductive synthetic fiber mesh sheet on the polymer film to form a plurality of transmission parts . Still another object of the present invention is to provide an electro-luminescent device having a large area for use in exterior signboards, which is manufactured by means of gravure printing or the like in such a way that a flexible front electrode film, which is wound in a roll, is continuously passed through between a plurality of rollers to sequentially form a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, on the flexible front electrode film.
[Advantageous Effects] According to the present invention, a flexible front electrode film comprises a transparent polymer film, having flexibility, tensile strength and elastic strength while blocking ultraviolet rays, and a front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film or by attaching a conductive fiber mesh sheet on the polymer film to form a plurality of transmission parts. Hence, even if the above film is wound in a roll, the conductive material is not damaged or detached. An electro-luminescent device of the present invention can be wound in a roll, by sequentially applying a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, throughout a flexible front electrode film having a plurality of transmission parts. Since the flexible front electrode film of the present invention can be wound in a roll, the electro- luminescent device having a large area can be manufactured on a large scale in such a way that the flexible front electrode film is continuously passed through between a plurality of rollers, thus fulfilling various demands of consumers . Moreover, since the electro-luminescent device of the present invention can be wound in a roll, it incurs low storing and transporting expenses, and can be easily used for various curved surfaces, and thus, it can serve as a self-luminescent film for exterior signboards having large areas.
[Description of Drawings] FIG. 1 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a first embodiment of the present invention; FIG. 2 is a schematic perspective view showing a mesh type front electrode layer, according to the first embodiment of the present invention; FIG. 3 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a second embodiment of the present invention; FIG. 4 is a schematic perspective view showing a mesh type front electrode layer, according to the second embodiment of the present invention; FIG. 5 is a partially enlarged perspective view showing a conductive synthetic resin sheet usable in the mesh type front electrode layer shown in FIG. 4; FIG. 6 is a schematic sectional view showing an electro-luminescent device using a flexible front electrode film, according to a third embodiment of the present invention; and FIG. 7 is a schematic sectional view showing the action of the electro-luminescent device using the flexible front electrode film, according to the present invention. ****Description of the Reference Numerals in the Drawings**** 10: electro-luminescent device 12 : flexible f ont electrode film 13: transparent polymer film 14 : mesh type front electrode layer 15: transmission part 16: luminescent layer 17 : insulating layer 18: rear electrode layer 19: protective layer 24: conductive material 25: transparent conductive material 35: conductive synthetic fiber sheet 241: wire 351 : wire [Best Mode] To achieve the above objects, a flexible front electrode film according to the present invention comprises a transparent polymer film having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays, and a mesh type front electrode layer formed on the polymer film by printing an opaque conductive material in a mesh pattern on the polymer film to regularly form a plurality of transmission parts having predetermined shapes. The opaque conductive material of the mesh type front electrode layer is a conductive polymer or a conductive metal paste. In addition, the opaque conductive material includes a polymer binder to manifest flexibility and elasticity. The transmission part of the mesh type front electrode layer is filled with a transparent conductive material. As such, the transparent conductive material is an ITO paste including a polymer binder. The transmission part of the flexible front electrode film constitutes 60% or more of the total area thereof. The width of the transmission part is 1-10 mm. Alternatively, a flexible front electrode film of the present invention comprises a transparent polymer film having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays, and a mesh type front electrode layer formed on the polymer film by attaching a conductive synthetic fiber sheet woven in a mesh pattern on the polymer film to regularly form a plurality of transmission parts having predetermined shapes . The conductive synthetic fiber sheet comprises a synthetic yarn having tensile strength and elastic strength and a conductive metal ion incorporated in or applied on the synthetic yarn. Further, an electro-luminescent device of the present invention comprises the flexible front electrode film, a luminescent layer having a predetermined thickness applied throughout the flexible front electrode film, an insulating layer having a predetermined thickness applied throughout the luminescent layer, a rear electrode layer having a predetermined thickness applied throughout the insulating layer, and a protective layer being resistant to moisture and ultraviolet rays and having a predetermined thickness applied on the rear electrode layer. The electro-luminescent device is continuously manufactured in a roll, and thus, is usable for exterior signboards having large areas. Hereinafter, a detailed description will be given of structures and actions of flexible front electrode films and electro-luminescent devices using the same, according to preferable embodiments of the present invention, with reference to the appended drawings. FIG. 1 is a schematic sectional view showing an electro-luminescent device 10, according to a first embodiment of the present invention. As shown in the drawing, the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a mesh type front electrode layer 14 formed on the polymer film by printing a conductive material in a mesh pattern on the polymer film to form a plurality of transmission parts 15. In addition, on the entire surface of the flexible front electrode film 12, a luminescent layer 16, an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially applied. In the electro-luminescent device 10 of the present invention, the mesh type front electrode layer 14 and the rear electrode layer 18 are connected with electrodes to which a predetermined alternating voltage is applied, so that light generated by the luminescent layer 16 is externally radiated through the plurality of transmission parts ,15. Since the electro-luminescent device- 10 is composed of the conductive material 24 having flexibility and elasticity printed in a mesh pattern on the flexible transparent polymer film 13 to form the plurality of transmission parts 15, even if it is wound in a roll, the front electrode layer is not damaged or detached. The transparent polymer film 13 is formed of a polymer material having flexibility to the extent that it may be wound in a roll, and has tensile strength and elastic strength to the extent that it is not torn or deformed when manufactured to have a large area. In addition, the transparent polymer film 13 should be transparent so that light radiated from the luminescent layer 16 can be sufficiently transmitted. For example, the transparent polymer film 13 is formed of a synthetic resin selected from among PVC (Polyvinyl Chloride) , PET (Polyethylene Terephthalate) , and PMMA (Polymethyl methacrylate) , and has a thickness of about 50 μm or more. When the electro-luminescent device 10 is continuously manufactured in a roll, the transparent polymer film 13 functions as a base substrate on which the plurality of coating layers including the mesh type front electrode layer 14 are sequentially applied, and also serves as a protective film for protecting the inner coating layers when being used for exterior signboards. Hence, the transparent polymer film 13 should have tensile strength and elastic strength to fulfill such functions and conditions. Further, the above polymer film may be integrated with a synthetic fiber mesh sheet which is not shown, to increase the tensile strength and elastic strength, if required. Furthermore, the above polymer film has an additive that blocks ultraviolet rays. The mesh type front electrode layer 14 formed on the transparent polymer film 13 comprises the conductive material 24 printed in a mesh pattern, as shown in FIG. 3. That is, as shown in the same drawing, the mesh type front electrode layer 14 including the conductive material 24 printed in a mesh pattern is structured so that a plurality of wires 241, each of which has predetermined width and thickness, are cross-linked to each other. In addition, inner spaces defined by the. cross-linked wires 241 are provided as rectangular transmission parts 15. As such, the conductive material 24 is a conductive polymer or a conductive metal paste having viscosity suitable for printing. For example, the conductive polymer is selected from among polyacethylene, polypyrrole, polythiophene, poly-biphenylene, N-methylphenolthiazine and polyphenothiazine . The conductive metal paste includes conductive metal powder made of copper, aluminum or silver mixed to a polymer binder. Thus, light transmittance of the conductive material 24 is slightly lowered. The mesh type front electrode layer 14 is formed by printing the conductive material 24 throughout the transparent polymer film 13 using a screen printing process or a gravure printing process. For example, in the case of screen printing, the transparent polymer film 13 is mounted to a screen printer, after which the conductive material 24 applied on a mesh screen is printed using a squeegee to form a mesh type front electrode layer 14. In the case of gravure printing, the transparent polymer film 13 wound in a roll is passed through between a plurality of printing rollers having a mesh pattern and corresponding pressing rollers, to form a mesh type front electrode layer 14. As such, the printing roller, which is supplied with the conductive material 24 from a conductive material source while being rotated at a predetermined speed on its axis, continuously prints the conductive material 24 on the transparent polymer film 13 to obtain the mesh type front electrode layer 14. The printed conductive material is securely adhered to the transparent polymer film 13 through heat treatment. In the present invention, the conductive material 24 of the mesh type front electrode layer 14 includes a certain polymer binder so as to retain flexibility and elasticity even after being dried. The transmission part 15 of the mesh type front electrode layer 14 is not limited to the shown shape, and may be formed in circular-, pentagonal-, circular-shapes, etc., so long as it fulfills desired transmittance and surface resistance. The wire 141 of the mesh type front electrode layer 14 has a width of 1-5 mm and a thickness of 5-30 μm, preferably 10-20 μm. If the mesh type front electrode layer 14 is too thick, flexibility and elasticity are lowered. Conversely, if the above layer is too thin, surface resistance becomes high. The transmission part 15 defined by the cross-linked wires 141 has a width of 1-10 mm. That is, the mesh type front electrode layer 14 is structured so that light generated by the luminescent layer 16 is externally radiated through the transmission part 15. To retain sufficient luminance, the area of the transmission part 15 should be as large as possible. However, if the total area of the wires 141 is too small, surface resistance is high, and hence, uniform luminescence is not realized or the device may break down due to partial overload. Therefore, the transmission part 15 preferably constitutes 60-70% of the total area of the mesh type front electrode layer 14. Turning now to FIG. 3, the section of an electroluminescent device 10 according to a second embodiment of the present invention is schematically shown. As shown in the same drawing, the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a conductive synthetic fiber mesh sheet 35 formed on the polymer film by attaching a conductive synthetic fiber mesh sheet 35 on the polymer film to form a plurality of transmission parts 15. In addition, on the entire surface of the flexible front electrode film 12, a luminescent layer 16, an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially formed. FIG. 4 is a perspective view showing the flexible front electrode film 12 formed by attaching the synthetic fiber mesh sheet 35 on the transparent polymer film 13. The synthetic fiber mesh sheet 35 is composed of a conductive fiber woven in a lattice form. Hence, the mesh type front electrode layer 14 includes a plurality of cross-linked wires 341 and rectangular transmission parts 15 defined by the cross-linked wires 341. As such, the conductive fiber is exemplified by a metal fiber, a carbon fiber, a fiber formed of synthetic resin incorporated with metal ion, a plated synthetic fiber, etc., in which the fiber formed of synthetic resin incorporated with metal ion is prepared by incorporating a copper ion in an acryl fiber and then reducing it. FIG. 5 is a schematic perspective view showing the synthetic fiber mesh sheet 35, according to the second embodiment of the present invention. As shown in the same drawing, the synthetic fiber mesh sheet 35 is composed of polyester yarns 351 woven at predetermined intervals, a conductive metal 353 having a predetermined thickness applied on the yarn 351, and black carbon 354 applied on the surface of the conductive metal 353 to protect the conductive metal 353. The conductive metal 353 is selected from among copper, silver, aluminum, etc. The yarn 351 is polyester having high tensile strength and elastic strength. The yarn 351 is preferably woven at a density of 80 numbers/inch2 or more to ensure sufficiently high tensile strength and elastic strength and decrease surface resistance. FIG. 6 is a schematic sectional view showing an electro-luminescent device 10 according to a third embodiment of the present invention. As shown in the same drawing, the electro-luminescent device 10 comprises a flexible front electrode film 12 including a transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays and a mesh type front electrode layer 14 formed on the polymer film to provide a plurality of transmission parts 15 on which a transparent conductive material 25 is applied to fill the transmission parts 15 with the transparent conductive material 25. Further, a luminescent layer 16, an insulating layer 17, a rear electrode layer 18 and a protective layer 19, each of which has a predetermined thickness, are sequentially formed on the entire surface of the flexible front electrode film 12. As such, the mesh type front electrode layer 14 is formed by printing the conductive material 24 in a mesh pattern on the transparent polymer film 13 or by attaching a certain synthetic fiber mesh sheet 35 on the transparent polymer film 13. The transparent conductive material 25 is formed of an ITO paste having a viscosity of 10,000-100,000 cps and 10-80 wt% solid content. The ITO paste is composed of ITO powder having low resistance mixed with a high-boiling- point solvent having a predetermined amount of molten resin. For example, 70 g of butyl carbitol acetate is mixed with 20 g of terpineol to form a mixture, in which 10 g of ethyl cellulose is then dissolved while being heated, to obtain a desired solvent. 70 g of the solvent is mixed with 30 g of ITO powder having a particle size of 0.2 μm while being stirred, to prepare an ITO paste. The ITO paste thus obtained has about 30 wt% solid content, and a viscosity of about 30,000 cps. Preferably, the transparent conductive material 25 is not applied thicker than the front electrode layer 14 so as to ensure flexibility to the extent of being able to be wound in a roll. The transparent conductive material 25 has preferably 50-90% transparency so that light generated by the luminescent layer 16 is sufficiently transmitted. The electro-luminescent device 10 of the present invention is manufactured by sequentially printing -the luminescent layer 16, the insulating layer 17, the rear electrode layer 18 and the protective layer 19, each of which has a predetermined thickness, throughout the flexible front electrode film 12 having the plurality of transmission parts. The electro-luminescent device 10 is preferably manufactured using the gravure printing process in such a way that the flexible front electrode film 12, which is wound in a roll, is continuously passed through between a plurality of printing rollers and corresponding pressing rollers (not shown) to sequentially form the above luminescent layer 16, the insulating layer 17, the rear electrode layer 18 and the protective layer 19 on the flexible front electrode film 12. The luminescent layer 16 is formed in such a way that the flexible front electrode film 12 is passed through between a plurality of rollers to be printed with a luminescent material (ZnS:Mn,Cl) having various activators and earth element impurities acting as a luminescent core added to ZnS powder or ZnF2 powder including a polymer binder therethroughout, and the printed material is dried at 100-140°C. The luminescent layer 16 has a thickness of 20-50 μm, and preferably 30-40 μm. The insulating layer 17 is formed in such a way that the luminescent layer 16 is passed through between a plurality of rollers to be printed with a mixture of insulating powder (BaTi03) and a cyano resin based polymer binder (MNA) therethroughout, and the printed mixture is dried at 100-150°C. The insulating layer 17 has a thickness of 5-30 μm, and preferably 15-30 μm. The rear electrode layer 18 is formed in such a way that the insulating layer 17 is passed through between a plurality of rollers to be printed with a conductive metal paste made of conductive metal powder, such as carbon, copper, silver or aluminum, mixed to the binder therethroughout. As such, it is preferable that the rear electrode layer 18 has light reflectiveness of 80% or more. The rear electrode layer 18 has a thickness of 5-20 μm. Further, it is preferably that an oxidation protective layer made of platinum, gold, silver or carbon be additionally formed between the rear electrode layer 18 and the protective layer 19. On the rear electrode layer 18, the protective layer 19, having a predetermined thickness and formed of a synthetic resin having high moisture resistance and blocking ultraviolet rays, is provided. The protective layer 19 having high moisture resistance is formed in such a way that the rear electrode layer 18 is passed through between a plurality of rollers to be printed with a molten synthetic resin therethroughout. The protective layer 19 has a thickness of 20-40 μm. The mesh type front electrode layer 14 and the rear electrode layer 18 are connected with electrodes (bus bars) having predetermined widths which are not shown. The electrodes are formed of copper, silver or aluminum. Referring to FIG. 7, the action of the electroluminescent device 10 is shown. The electro-luminescent device 10 manufactured in a roll is used in various sizes and forms. When a predetermined alternating voltage is applied to the electrodes which are connected to the mesh type front electrode layer 14 and the rear electrode layer 18, light emitted from the luminescent layer 16 is externally radiated through the transmission parts of the mesh type front electrode layer 14. At this time, a part of light emitted from the luminescent layer 16 is directed toward the rear electrode layer 18, and then reflected from the rear electrode layer 18. The reflected light is externally radiated through the transmission parts 15, thereby increasing luminescent efficiency. In this way, the transmission part 15 of the mesh type front electrode layer 14 constitutes 60-70% of the total area thereof. Thus, light can be emitted at sufficient luminance, and as well, the front electrode 141 of the mesh type front electrode layer 14 are uniformly distributed to constitute 30-40% of the total area thereof. Thus, the mesh type front electrode layer 14 can manifest sufficiently high conductivity. Moreover, the electroluminescent device 10 of the present invention can be wound on a roll having a diameter of 200-300 mm, since it includes the transparent polymer film 13 having flexibility and predetermined tensile strength and elastic strength and the mesh type front electrode layer 14 having flexibility and elastic strength formed thereon. Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims .

Claims

[CLAIMS] [Claim l] A flexible front electrode film, comprising: a transparent polymer film having a predetermined thickness with flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays; and a mesh type front electrode layer formed on the transparent polymer film by printing a conductive material in a mesh pattern on the transparent polymer film to form a plurality of transmission parts having predetermined shapes .
[Claim 2] The flexible front electrode film according to claim 1, wherein the conductive material of the mesh type front electrode layer comprises a conductive polymer having flexibility and predetermined elastic strength.
[Claim 3] The flexible front electrode film according to claim 1, wherein an opaque conductive material of the mesh type front electrode layer comprises a conductive metal paste having flexibility and predetermined elastic strength.
[Claim 4] The flexible front electrode film according to claim
2 or 3, wherein the conductive polymer or the conductive metal paste of the mesh type front electrode layer is mixed with a polymer binder exhibiting flexibility and predetermined elasticity.
[Claim 5] The flexible front electrode film according to claim 1, wherein the transmission part of the mesh type front electrode layer constitutes 60-70% of the total area of the mesh type front electrode layer.
[Claim 6] The flexible front electrode film according to claim 1 or 5, wherein the transmission part of the mesh type front electrode layer has a width of 1-10 mm.
[Claim 7] The flexible front electrode film according to claim 1, wherein the transmission part of the mesh type front electrode layer is filled with a transparent conductive material .
[Claim 8] The flexible front electrode film according to claim 7, wherein the transparent conductive material is an indium tin oxide paste including a polymer binder.
[Claim 9] A flexible front electrode film, comprising: a transparent polymer film having a predetermined thickness with flexibility and predetermined tensile strength and elastic strength while blocking ultraviolet rays; and a mesh type front electrode layer formed on the transparent polymer film by attaching a conductive synthetic fiber sheet woven in a mesh pattern on the transparent polymer film to form a plurality of transmission parts having predetermined shapes.
[Claim 10] The flexible front electrode film according to claim 9, wherein the conductive synthetic fiber comprises a synthetic yarn having tensile strength and elastic strength and a metal ion incorporated in or applied on the synthetic yarn.
[Claim 11] The flexible front electrode film according to claim
9, wherein the transmission part of the mesh type front electrode layer is filled with a transparent conductive material .
[Claim 12] The flexible front electrode film according to claim 11, wherein the transparent conductive material is an indium tin oxide paste including a polymer binder.
[Claim 13] An electro-luminescent device, comprising: A flexible front electrode film including a transparent polymer film and a mesh type front electrode layer having a plurality of transmission parts; and a luminescent layer, an insulating layer, a rear electrode layer and a protective layer, each of which has a predetermined thickness, sequentially formed throughout the flexible front electrode film.
[Claim 14] The electro-luminescent device according to claim 13, wherein the mesh type front electrode layer, the luminescent layer, the insulating layer, the rear electrode layer and the protective layer are sequentially formed on the transparent polymer film in such a way that the transparent polymer film, which is wound in a roll, is continuously passed through between a plurality of rollers.
PCT/KR2004/003372 2003-12-22 2004-12-21 Flexible front electrode films and electro-luminescence devices using the same Ceased WO2005062679A1 (en)

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