CA2257224A1 - Process and materials for imagewise placement of uniform spacers in flat panel displays - Google Patents

Process and materials for imagewise placement of uniform spacers in flat panel displays Download PDF

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Publication number
CA2257224A1
CA2257224A1 CA 2257224 CA2257224A CA2257224A1 CA 2257224 A1 CA2257224 A1 CA 2257224A1 CA 2257224 CA2257224 CA 2257224 CA 2257224 A CA2257224 A CA 2257224A CA 2257224 A1 CA2257224 A1 CA 2257224A1
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CA
Canada
Prior art keywords
receptor
spacer layer
transferable
donor sheet
layer
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.)
Abandoned
Application number
CA 2257224
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French (fr)
Inventor
John S. Staral
Claire A. Jalbert
William A. Tolbert
Martin B. Wolk
Allan R. Martens
Thomas A. Isberg
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3M Co
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Individual
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Publication of CA2257224A1 publication Critical patent/CA2257224A1/en
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    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1339Gaskets; Spacers; Sealing of cells
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/40Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography
    • B41M5/42Intermediate, backcoat, or covering layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/382Contact thermal transfer or sublimation processes
    • B41M5/38207Contact thermal transfer or sublimation processes characterised by aspects not provided for in groups B41M5/385 - B41M5/395
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/40Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography
    • B41M5/46Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography characterised by the light-to-heat converting means; characterised by the heat or radiation filtering or absorbing means or layers
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1339Gaskets; Spacers; Sealing of cells
    • G02F1/13394Gaskets; Spacers; Sealing of cells spacers regularly patterned on the cell subtrate, e.g. walls, pillars
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/382Contact thermal transfer or sublimation processes
    • B41M5/392Additives, other than colour forming substances, dyes or pigments, e.g. sensitisers, transfer promoting agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/382Contact thermal transfer or sublimation processes
    • B41M5/392Additives, other than colour forming substances, dyes or pigments, e.g. sensitisers, transfer promoting agents
    • B41M5/395Macromolecular additives, e.g. binders
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/26Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
    • B41M5/40Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography
    • B41M5/41Base layers supports or substrates
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/913Material designed to be responsive to temperature, light, moisture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/914Transfer or decalcomania
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24901Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/25Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/28Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2813Heat or solvent activated or sealable
    • Y10T428/2817Heat sealable
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/28Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2813Heat or solvent activated or sealable
    • Y10T428/2817Heat sealable
    • Y10T428/2826Synthetic resin or polymer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/28Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2848Three or more layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]

Abstract

Process and materials are described for selectively placing uniform spacers on a receptor. Spacer elements are placed on a receptor by selectively irradiating a thermal transfer donor sheet comprising a transferable spacer layer. The transferable spacer layer may include particles or fibers to form a composite. The particles may have a spacing dimension either greater than or less than the thickness of the transferable layer. When the spacing dimension of the particle is greater than the thickness of the transferable layer, then the spacing dimension of the particles controls the spacing distance. The process and materials are useful in the manufacture of flat panel displays, particularly, liquid crystal display devices.

Description

CA 022~7224 1998-12-02 W O 97/50016 PCT~US96/16943 PROCESS AND MATERIALS FOR IMA~;Wl~; PLA~.MF.l~T OF
UNIFORM SPACERS IN FLAT PANEL DISPLAYS

Field of the Invention s The present invention relates to a process and materials for pl~cement of spacers onto a receptor which provide uniform spacing and structural support in flat panel displays. More particularly, this invention relates to the precise pl~cement of spacers using a thermal transfer donor sheet and an imaging radiation source.
o Ba- k~round of the Art Control of the spa~ings and meçh~nical forces within the construction of a flat panel display (i.e., liquid crystal displays, electroluminescPnt displays, vacuum fluorescent displays, field emission displays, and plasma displays) is often critical to the performance of the corresponding device and depPnrlc upon the incorporation of physical spacers into the corresponding display. For example, in liquid crystal displays (LCDs), the polarization of the light exiting the display is controlled in part by the optical path length through the liquid crystal layer. In current display te~hnology~ the th;~nPss of the liquid crystal layer is det~ ed by spacers, which may be in the form of particles (i.e., spherical beads or fibers), columnar structures (i.e., posts or pillars), microribs, etc. Spacers have become increasingly hllpol lalll with the desire for light-weight large format displays. To achieve lighter weight display panels, 11 .lnsp~ ent polymeric substrates are typically used since they are much lighter than glass. However, polymeric substrates are more flexible; thus, ~e4ui.ing a denser population of spacers to 25 ~ a ulfiro-.n th~ nPc.c throughout the display panel. The most common and inexpensive method for controlling the th:eL nçss of the liquid crystal layer is to deposit a random arr~n~çment of particles having a narrow size distribution overthe entire surface of the substrate or ~lignn~ent layer. This process has an obvious disadvantage in that there is no control over the p!ncçment ofthe particles le~ g in a high pelct;lllage ofthe particles appe&ling in the display windows, thus decreasing the amount of light that may pass through the display. In many . .

CA 022~7224 1998-12-02 W O 97150016 PCTrUS96/16943 applications, the particles are not anchored to the substrate and may shift or migrate causing artifacts to appear in those areas in the display cell. The spray application presents an additional issue in the m~mlf~cturing process. The display is assembled in Class 10 to 100 cleanrooms to meet the optical quality s re4uirel~nts for the liquid crystal displays. Spraying particles onto a surface results in many of the particles becol.,n~g airborne, thus making it difficult to ..,~il"~i" Class 10 to 100 standards. The thinner the layer desired the smaller the particle required which leads to increased h~n-lling and applir~tion ~ icllltieeOne attempt to overcome the dçfici~nriçc in liquid crystal displays as 0 described above is disclosed in U.S. Patent No. 4,720,173 and J~panese Patent applications, JP 7325298,JP 5203967, and JP 2223922 where a photoresist m~t~ri~l is bonded to the substrate, imaged and developed to generate spacer entities. This method allows one to more precisely place the spacer on the substrate; however, the requirel..ent of a developing step adds an additional step 1S to the process. Liquid development also produces spent developer solutionc which must be disposed of. Many of the developers contain solvents or have a high pH, thus requiring special h~nt~ling for safety and/or special disposal to meet federal and state e.lviroll....,1~1 re~ tiom It is also more difficult to m~int~in a uniform th; -l n~cc of the spacers when a photoresist is used. For example, the 20 developer may etch away more of the surface in one area than in another.
An ~ltern~tive approach for controlling spacing in liquid crystal displays is described in U.S. Patent No. 5,268,782; where, a microstructured substrate is used as both a substrate and a spacer integrated into one çl~m~nt To ...;lf....;~e interferences in the window areas, the microstructured surface typically con~p-;ses 2s a series of parallel ridges (microribs). Even though the percentage of spacers within the optical window is ...;..;...;,e-~, a ~ipl)ing effect is visible in the display.
Additionally, the deposition of the high viscosity liquid crystals is more arduous when microribs are used for spacers. For in.cl~nce, it is harder to apply the high viscosity liquid crystals without ell~ pillg air which creates an optical defect in 30 the layer.

CA 022~7224 1998-12-02 Clearly there is a need for a method and materials for accurate pl~qc~ment of structurally supporting spacers which are cost effective, reliable, and elimin~e interference with the optical integrity of the display panel.

Summar~ of the Invention The present invention overcomes the d~firienries of the prior art by employing a method and materials for placçrnent of structurally supporting spacers on a receptor using a thermal ll~lsrer donor sheet and im~ging radiation to accurately place uniform spacers in desien~ted locations outside the display o windows.
The present invention provides a thermal ~ srer donor sheet com~ i"g, (a) a support, (b) a l~sre~able spacer layer, and (c) an optional adhesive layer.
At least one of the receptor, support, ~ relable spacer layer and adhesive layercontains a radiation absorber which converts a portion of the im~ine radiation to heat. The im~gin~ radi~tion provides the means for selectively transferring the l, ~n~re, ~ble spacer layer to a receptor to form spacer elements on the receptor.
An alternative thermal donor sheet construction is provided which comprises; (a) a support, (b) a light-to-heat conversion layer con~;ni~e a firstradiation absorber, (c) a transferable spacer layer, and (d) an optional adhesive layer. The thermal ll~nsrèr donor sheet may optionally include a non-llansrelable interlayer interposed between the light-to-heat conversion layer and the transferable spacer layer. A second ra~ tion absorber may be present in the receplor, support, non~ ;.Çe,able interlayer, l,~,sre,~ble spacer layer or adhesive layer The ll~nsre,~ble spacer layer may be either a non-composite organic material or a composite co,-lai~ g particles having spacing dimensions which areeither smaller than or larger than the ll"ch.ess of the ll~;,rel ~ble spacer layer.
When the spacing ~ enQions of the particles are smaller than or equal to the Shir~ness ofthe llansrt;l~ble spacer layer, then the thic~n~oss ofthe ll~l~rel~ble layer controls the spacing dist~nce bet~,veen the receptor and an addition~l substrate atta~hed to the spacer elen. ~ in f~ ling a flat panel display device.

CA 022~7224 1998-12-02 W O 97/50016 PCT~US96/16943 When the spacing dimrn~iQns of the partic}es are greater than the thicL ness of the llafisr~lable spacer layer, then the spacing dimensions of the particles control the spacing ~1ict~nre within the flat panel display.
In another embodiment, a process is described for selectively placing spacer çl~m~ntc on a receptor for use in a flat panel display inchlding the steps of:
(1) providing the thermal l,~rt;l donor sheet described above, (2) placing in intinn~te contact the receptor with the ~ rt;l~ble spacer layer ofthe thermal transfer donor sheet, (3) irr~di~ting at least one ofthe thermal ~ar~rer donor sheet or the receptor in an imagewise pattern with im~ing radiation such that the o ra~i~tion absorber in either the receptor or thermal transfer donor sheet construction absorbs a portion of the im~gjng radiation and converts that radiation to heat, (4) llansr~lling the transferable spacer layer in the irradiated areas to the receptor, and (5) removing the thermal ~ srer donor sheet to form spacer elements coll~sl~onding to the irradiated areas on the receptor.
In yet another embodim~nt~ a process is described for use in constructing a liquid crystal display device wherein the above described process further inrllldes the steps of (6) ~tt~chi~ the spacer ~1~,."~ to a substrate to form cavities between the substrate and the receptor, (7) filling the cavities with liquid crystal materials, and (8) sealing the periphery of the substrate to the receptor.
As used herein the phrase "in intim~te contact" refers to suffirient contact between two sllrf~~es such that the ll~r,srer of materials may be accompiiched during the im~ging process to provide s~lffirient l~u.sre~ of material within the thermally addressed areas. In other words, no imperfections are present in the imaged areas which render the article non-fi.nction~l 2s "Spacers" or "spacer elemrnt~" refer to çlçm~nt.c which provide a means of separa~i"g two parallel substrates (or supports) and may also provide structuralsupport for one or both of the same two parallel sul,stl ~les.
"Spacing rlim~nQ;on" refers to the spacing ~ t~nce betv~en two parallel substrates provided by the spacer el~ ~~.er,1~ For those spacer element~ based on a 30 non-composite organic material or a composite material wherein the composite co~ c particles which are smaller than the ~ LllCSS of the Ll~llsr~lable spacer CA 022~7224 1998-12-02 W O 97/50016 PCT~US96/16943 s -layer, the spacing dimPn~;on is equal to the thic~n~cs of the spacer layer.
However, when the composite contains particles having spacing dimensions that are greater than the thickness of the transferable spacer layer, the spacing dimension is equal to the ~i~met~r or height ofthe particles as oriented perpPndic .l~r to the substrates. In other words, if the particles are spherical in shape, then the ~i~met~r of the sphere is the dim~n~ion measured. If the particles are cylindrical in shape (i.e., rods), then the ~ meter of the cylinder is used if the cylindrical particles are oriented such that the circular dimension is perpen~lic~ r to the substrate. However, when the cylindrical shaped particles are oriented such 0 that the length of the cylindrical particles are perpen~lic~ r to the substrates (i.e., pillar between the substrates), then the height of the cylinder is used as the spacing dimension.
~'Tm~ing radiation" refers to energy from a radiation source that can cause an image-wise transfer of a mass transfer layer from a therrnal transfer donor sheet to a receptor (or substrate).

Detailed Descri~tion of the Invention The present invention relates to a process for placing spacer elpm~ntc on a receptor (or substrate) for use in a flat panel display. The spacer Plem~nt~ areplaced on the receptor by selectively irr~ tin a therrnal l, ~nsrer donor sheet colll~lisillg, in order: (a) a support, (b) an optional light-to-heat conversion layer, (c) an optional non-transferable interlayer, (d) a ll~srt;,able spacer layer and (e) an optional adhesive layer. The process in~hldes the following steps: (i) placing in intim~te contact a .eceptor and the therrnal transfer donor sheet described above, (ii) irra.li~tin~ at least one of the therrnal transfer donor sheet or the receptor (or a portion thereof, i.e., substrate, spacer layer, interlayer, light-to-heat conversion layer, and/or adhesive layer) with im~ing radiation to provide sufficient heat in the irradiated areas to ll~ re~ the spacer layer to the receptor, and (iii) Lrdllsre.l;llg the transferable spacer layer in the irradiated areas to the receptor.
The therrnal transfer donor sheet of the present invention can be prep~ ed by depositing layers (b), (c), (d) and/or (e) described above onto a support. The CA 022~7224 1998-12-02 W O 97/50016 PCTrUS96/16943 support may be constructed of any material known to be useful as a support for athermal transfer donor sheet. The support may be either a rigid sheet material such as glass or a flexible film. The support may be smooth or rough, transparent, opaque, tr~n~ cent sheet-like or non-sheet-like. Suitable film supports include 5 polyesters, especially polyethylene terephthql~te (PET), polyethylene naphth~late (PEN), polysulfones, polystyrenes, polycarbonates, polyimides, polyamides, cell..lose esters such as, cellulose acetate and cellulose butyrate, polyvinyl chlorides and derivatives thereof, and copolymers comprising one or more of the above materials. Typical thic~nesses of the support are between about 1 to 200 o microns.
The 1- ~sre, ~ble spacer layer may include organic materials or alternatively a composite co-.,~ ;ng organic materials having incorporated therein particles or fibers. Suitable materials include any number of known polymers, copolymers, oligomers and/or l-.ono...el ~. Suitable polymeric binders include materials such as hPrmoset therrnosett~hle, or thermoplastic polymers, inrl~lrling phenolic resins(i.e., novolak and resole resins), polyvinyl~cet~tes, polyvinylidene chlorides, polyacrylates, cellulose ethers and esters, nitrocelluloses, polycarbonates, polysulfones, polyesters, styrene/acrylonitrile polymers, polystyrenes, cellulose ethers and esters, polyacetals, (meth)acrylate polymers, polyvinylidene chloride, 20 a-chloroacrylonitrile, maleic acid resins and copolymers, polyimides, poly(amic acids), and poly(amic esters) and mixtures thereof.
When the transferable spacer layer includes a thermosettable binder, the thermosettable binder may be cro.~.~linl~ed after ,.an~re. to the receptor. The binder may be crosclinl~ed by any method which is appropliate for that particular 25 thermosett~hle binder, for example, exposing the thermosettable binder to heat, irra~ ting with a suitable ra~i~tion source, or a chemical curative.
Particles or fibers may be added to the l.~nsre.able spacer layer to form a composite. The addition of particles or fibers to the llansr~.~ble spacer layer may be accomplished by using any known particle or fiber with a spacing dimen~ion 30 less than or equal to the spacing required in the particular display device of interest. The particles may have a spacing dimension smaller than the thickness of CA 022~7224 1998-12-02 W O 97150016 PCT~US96/16943 the tl~srel~ble spacer layer or a spacing dimension larger than the thickness ofthe ~ srw able spacer layer. When the particle size is smaller, the thickness of the transferable spacer layer controls the spacing within the display device. Whereas, when larger particles are used the spacing dimension of the particles used in the s composite controls the spacing in the display device. Preferably at least 5% ofthe particles have a spacing dimension greater than the thickness of the spacer layer and more preferably at least 10%. Either approach may be used as a means for achieving uniform separation and support of the substrates within the display.
Suitable particles include organic and/or inorganic materials (solid or hollow) o having any suitable shape (i.e., spheres, rods, posts, triangles, and ll~pezoids) and size distribution consistent with m~ g the desired separation. ~l~re"ed particles include current LCD spacer spheres, rods, etc. comprised of glass or plastic such as those .er~- cnced in Japonese Kokai Patent Application No. HEI
7[1995]-28068; U.S. Patent Nos. 4,874,461; 4,983,429; and 5,389,288. In LCD
5 displays, it is prere"ed that the standard deviation for the size distribution of particles is + or - 20% ofthe mean particle spacing dimension (i.e., mean di~metçr of a spherical or cylindrical shaped particle, or average height of a cylindrical shaped particle). More pr~re.~bly, the standard deviation is + or - 10% ofthe mean. Most preferably, the standard deviation is + or - 5% of the mean. When a 20 fiber is used, the dimensions are typically measured as the denier (or finen~) of the fiber. The length of the fiber is preferably less than the ~ meter of the srt; ~ed spacer çl~m-o,nt Dispersants, surf~ct~nt~ and other additives (i.e., antioxi~nt~ Iight stabilizers, and coating aides) may be inrl~lded to aide in the dispersion ofthe2s particles and/or fibers or impart other desirable propt~ lies to the 11 ~&sre dble spacer layer as known to those skilled in the art.
The co",p,~ss;bili~y ofthe ele~ bearing the forces in the display (e.g., the particles in the case where the spacer layer comprises particles with a particle spacing ~1imçn~ion greater than the thir~ness of the transferable spacer layer and 30 the ~l~r,;,r~,able spacer layer in cases where the spacer layer does not co.mrri~e particles with particle spacing dimeneions greater than the thir~nç~c of the .. . . ... .. . . .. .. . . .

CA 022s7224 1998-12-02 W O97/50016 PCTrUS96/16943 transferable spacer layer) should be s-lffirient to m~int~in a uniform spacing gap in the corresponding display.
The thermal l-~a~e- donor sheet may also include other ingredients known to be useful with mass l~r.srer donor sheets, such as radiation (or light) absorbing materials that absorb the im~ ng radiation and converts that radiation energy into heat energy, thus f~ ilit~tir~ rel of the transferable spacer layer from the donor sheet to a receptor. The radiation absorbing material may be any material known in the art that absorbs a portion of the incid~ont im~ng radiation and converts that im~ging r~ tion energy to heat energy. Suitable radiation 0 absorbing materials include absorbing dyes (i.e., dyes that absorb light in the ultraviolet, infrared, or visible wavelengths), binders or other polymeric materials, organic or inorganic pigments that can be a black-body or non-black-body absorber, metals or metal films, or other suitable absorbing materials.
F.Y~mples of radiation absorbing materials that have been found to be particularly useful are infrared absorbing dyes. Descriptions of this class of dyes may be found in Matsuoka, M., Infrared Absorbing Materials, Plenum Press, New York, 1990, in ~t~1Ql ~ M., Absorpffon Spectra of DyesforDiode Lasers, Bunshin Publishing Co., Tokyo, 1990, in U.S. Patent Nos. 4,772,583; 4,833,124;
4,912,083; 4,942,141; 4,948,776; 4,948,777; 4,948,778; 4,950,639; 4,940,640;
4,9S2,552; 5,023,229; 5,024,990; 5,286,604; 5,340,699; 5,401,607 and in European Patent Nos. 321,923 and 568,993. Additional dyes are described in Bello, K. A. et al., J. Chem. Soc., Chem. Commun., 452 (1993) and U.S. Patent No. 5,360,694. IR absorbers marketed by American Cyanamid or Glendale Protective Technologies under the design~fion IR-99, IR-126 and IR-165 may 2s also be used, as disclosed in U.S. Patent No. 5,156,938. In addition to conventional dyes, U.S. Patent No. 5,351,617 describes the use of IR-absolbing conductive polymers as ra.li~tion abso,l,ing materials.
Other l . ~...ples of pre~,.ed r~ tion absorbing materials include organic and inol~ic abso-l,;ng materials such as carbon black metals, metal oxides, or 30 metal s~llfi-lçs R~prcsc.-l~ re metals include those met~llic ele-. .- - .1 ~ of Groups Ib, IIb, IIIa, IVa, IVb, Va, Vb, VIa, VIb and VIII of the Periodic Table, as well as CA 022~7224 1998-12-02 alloys thereof, or alloys thereof with element.~ of Groups Ia, IIa, and IIIb, ormixtures thereof. Particularly pl~r~.-ed metals include Al, Bi, Sn, In or Zn, and alloys thereof or alloys thereof with ~lPmPnt~ of Groups Ia, IIa and IIIb of thePeriodic Table, or compounds or mixtures thereo~ Suitable compounds of these 5 metals include metal oxides and sulfides of Al, Bi, Sn, In, Zn, Ti, Cr, Mo, W, Co, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zr and Te, and mixtures thereof.
The radiation absorbing material may be present in the thermal l, acsfe donor sheet as a separate layer, commonly referred to as a "hght to heat conversion layer" (LTHC), interposed bclv~eell the support and the transferable 0 spacer layer. A typical light to heat co,.~e,~ion layer in~ des one or more layers of organic or inorganic materials that are capable of absorbing the ims~ng radiation and are plefe-ably thermally stable. It is also desirable that the light to heat conversion layer remain s~lbsl;...l.~lly intact during the im~eing process.When a metallic film is used for the light to heat conversion layer, the metallic layer plefelably has a thic~ne~s between 0.001 to 10 ~m, more prefel~bly between0.002 to 1.0 llm.
Alternatively, a light to heat conversion layer may consist of light absorbing particles (i.e., carbon black) dis~,elsed in a binder. Suitable binders include film-forrning polymers such as thermoset, thermosett~ble, or thermoplastic polymers, such as phpnolic resins (i.e., novolak and resole resins), polyvinyl~Get~tes polyvinylidene chlorides, polyacrylates, cellulose ethers and esters, nitrocelluloses, polycall)o.la~es, and llu~-lures thereof. When this type of light to heat conversion layer is used, the dry coating th;c1~ness is prerelablybetween 0.05 to 5.0 miclo,ll~le.s (llm), more preferably 0.1 to 2.0 llm.
2s When the LTHC layer is present, an optional non~ nsrt;-able interlayer may be interposed b~ n the transferable spacer layer and the LTHC layer. The incorporation of a inlellàyer reduces the level of cor~ ;on ofthe resulting transferred image from the light-to-heat conversion layer and decreases the amount of distortion in the ll~s~lled image. The interlayer may be either an 30 organic or inorganic material. To ;; i7e damage and con~ tion ofthe transrelled spacer ~lement the interlayer is preferably a continllous coating which .. . . . . . . .

CA 022~7224 1998-12-02 -has a high thermal r-Pcict~nce and remains sub~ ially intact and in contact withthe LTHC layer during the im~in~ process. Suitable organic materials include both thermoset (crosclin~-ed) and thermoplastic m~t~rialc The interlayer may be either tr~ncmiccive or reflective at the im~in~ radiation wavelength output.
Suitable thermoset resins useful in the interlayer include both thermal- and radiation-crosslinked materials, such as crosslinked poly(meth)acrylates, polyesters, epoxies, and polyureth~nPc For ease of applic~tion, the thermoset materials are usually coated onto the light-to-heat conversion layer as thermoplastic precursors and subsequently crocclinked to form the desired o crocclinL--pd interlayer. Classes of suitable thermoplastic materials include polysulfones, polyesters, and polyimides. The thermoplastic interlayer may be applied to the light-to-heat conversion layer using conventional coating techniques (i.e., solvent co~tin~ spray co~tin~ or extrusion coating). The optimum thickness ofthe i,.le~layer is d~ ed by the .. ;n:.. th;~L-n~cc at which transfer ofthe 5 light-to-heat conversion layer and distortion ofthe ~ sr~"Gd spacer layer are Plimin~terl, typically bclweel- 0.05 llm and 10 ~,lm.
Suitable inorganic materials for use as interlayer materials include metals, metal oxides, metal s ~lfides, and inorganic carbon coatings, which are highly tr~ncmicsive at the im~in~ radi~tion wavelength and may be applied to the light-20 to-heat-conversion layer using conv~ntio~l techniques (i.e., vacuum sputtering, vacuum evaporation, or plasma jet). The opli,..um l'ic~ness is determined by theminim..m tl.icL ...-cc at which l.~.arer ofthe light-to-heat conversion layer and distortion ofthe llallsrelled layer are elimin~tptl~ typically between 0.01 ,~lm and 10 ~Im.
The thPrm~l transfer donor sheet may include an optional adhesive layer avercoated on the surface of the tr~ncfpr~hle spacer layer. The adhesive layer provides improved transfer of the tr~n~fP~r~hle spacer layer to a lcce~lor by means of a thermally activated adhesive. The adhesive topcoat is preferably colorless;however, in some appli~tion~ a tr~n~lucent or opaque adhesive may be desirable to enh~n~e the cQIln~l of the display or to provide special effects. The adhesive layer is preferably non-tacky at room ~ pP~ J ~ ~;. The adhesive layer may also _ include a light absorbing material to further assist the transfer efficiency of the image. Pn,f~l~d adhesives include thermoplastic materials having melting le."p~.dtures between a~p~ ly 30~C and 110~C. Suitable thermoplastic adhesives include m~tP~ c such as poly~mides, polyacrylates, polyesters, polyureth~nes, polyole~ms, poly~lyle~s, polyvinyl resins, copolymers and combination thereof. The adhesive may also include thermal or photochemic~l crosclinkPrs to provide thermal stability and solvent rPcict~nce to the t-~ncfprred image. Crosslinkers include monomers, oligomers and polymers which may be crocclinl~l thermally or photocll~omi~lly by either estprn~l initiator systems or 0 internal self-initi~tin~ groups. Thermal crosclinkers include m~tPri~lc capable of crosclinking when subjected to thP.rm~l energy.
Alternatively, radiation absorbing materials may be inco,yo,~ted into the receptor, or in a separate topcoat deposited on the surface of the receptor (i.e., a black matrix on the receptor, an adhesive topcoat deposited on the surface of the lS receptor) to assist in the transfer of the spacer layer to the receptor. If the ra~ tion absorbing material is present in the receptor, or is in a portion ofthethermal transfer donor sheet that is ll,tnsre"ed to the receptor during im~ejng process, then it is prefe" ~d that the radiation absorbing material not interfere with the performance prope~lies (i.e., the desired optical prope,lies) ofthe imaged 20 receptor.
The receptor may be any flat panel display ~le~ t ben~rl~ g from the application of spacers. The spacers are precisely placed in the desired locations to avoid optical int~,~t;, ence in the display windows of the display device. The receptor may be optionally coated with an adhesive topcoat to f~r~ te the 2s transfer of the ~ s~ ~ble spacer layer to the receptor. The receptor may alsohave deposited on the surface a black matrix to enh~nce viewing contrast. The black matrix may be formed by deposition of inorganic (i.e., metal andlor metal oxides, and metal sulfides) or organic materials (i.e., dyes in an organic binder) or a co",binalion of both (i.e., carbon black dispersed in a binder). The black 30 matrices generally have a th~ ness b~ween 0.005 to 5 microns. Typically, the receptor has a il ~Irness between 1 to 2000 microns.

CA 022~7224 1998-12-02 W O 97/50016 PCTrUS96/16943 In the practice of the present invention, the thermal im~ging el~mPnt is positioned such that upon application of the ima~ing radiation (or light), the LTHC layer absorbs the im~ging radiation and converts it to heat in the irradiated areas which in turn promotes the transfer of the transferable spacer layer in the s irradiated areas to form the spacer elements on the receptor.
The formation of the spacers may be effected by appropriate modulation of a im~ging radiation source or by exposure through a mask. The spacers may be precisely placed in the desired locations to avoid optical interference in the display windows of the display device. A variety of light-emittin~ sources can be utilized 0 in the present invention inrlutiing flash lamps, high powered gas lasers, inrrared, visible, and ultraviolet lasers. In an analog system, a mask is used to selectively filter the radiation in an imagewise pattern corresponding to the desired spacerlocations. Flash lamps having sufficient energy output to 1, ~rer the spacer layer may be used in the analog systems. In a digitally addressed system, a laser or laser 5 diode is typically used to imagewise transfer the spacer layer onto the substrate in the desired spacer locations. Plefe~ed lasers for use in this invention include high power (>100 mW) single mode laser diodes, fiber-coupled laser diodes, and diode-pumped solid state lasers (i.e., Nd:YAG and Nd:YLF), and the most prefe~ed lasers are diode-pumped solid state lasers. In both the analog and 20 digitally addressed systems, the spacers may be precisely placed in the desired locations to avoid optical interference in the display windows of the display device. Since the spacers are selectively transferred from the thermal l,ans~r elemrnt onto the substrate, no liquid process steps are nec~c.c~.y to develop the image. The direct im~ging process elimin~tes the need for additional equipment, 25 additional process steps to develop the image and disposal of spent developers.
During lasèr exposure it may be desirable to ...;~ e formation of interference pattern due to multiple reflections from the imaged material. This can be accompliched by various methodc The most common method is to effectively roughen the surface of the therrnally imageable element on the scale of the inri~çn im~gin~ radiation as described in U.S. Patent. No. 5,089,372. An alternate method is to employ the use of an anti-reflection coating on the second interface r CA 022~7224 1998-12-02 that the incident illllmin~tion encounters. The use of anti-reflection coatings is well known in the art, and may consist of quarter-wave thicknesses of a coating such as m~ nPsil~m fluoride, as described in U.S. Patent No. 5,171,650. Due to cost and m~nuf~ctllring cons~a;l~s~ the surface rou~hPning approach is p.t;re"eds in many applications.
A r~,ese~ tive application of the process for using the thermal transfer donor sheet described herein for selective placement of spacers on a substrate is in the manufacture of liquid crystal display devices. A twisted nematic display device is an example of a typical liquid crystal display, which comprises a cell or o envelope formed by placing a pair of transparent, planar substrates, in register, overlying and spaced apart from one another using spacer elements. The periphery of the substrates are joined and sealed with an adhesive sealant usually applied by a screen plillting techni~ue to provide an enclosed cell. The shallowspace or cavity between the spacer elPment~ on the subsllales is filled with liquid crystal materials just prior to final sealing. Conductive, transparent electrodes are arranged on the inside surface of the substrates in either a segmented or X-Y
matrix design to form a plurality of picture elementc .AlienmPnt coatings are applied to portions of the interior surface of the liquid crystal display cell to cause a desired olie.,lalion ofthe liquid crystal material at its interface with the surface 20 of the display. This ensures that the liquid crystal rotates light through angles which are comple~..c~ y to the ~ligllment ofthe polarizers associated with the cell. Polarizing ele~ent~ are optional depending on the type of display and may be associated with one or more surfaces of the display when used. A reflector cle~ lll may be associated with the bottom substrate when a reflective rather an a 25 l~nc~ re display is desired. In that event, the bottom substrate may not haveto be l,~nspalenl. The lt;ce~r may optionally contain an ~lignmP.nt layer coatedon the surface, in which case, the spacers are applied to the ~lignnlent layer.
The spacers are placed on the lece~t(,r (or ~lignmpnt layer) using the process previously described by selectively in~ ting the thermal transfer donor 30 elPment in intim~tP. contact with the receptor.

... ~ .. ~ .. .. . . .

CA 022~7224 1998-12-02 The components and assembly techniques of liquid crystal displays as described above are well known. For example, general details for assembly may be found in "Materials and Assembling Process of LCDs" Liquid Crystals-Applicalions and Uses, Bitendra R~h~rlnr, Ed., World Sri~ntific Publishing Co.
s Pte. Ltd., Volume 1, Chapter 7 (1990).
The following non-limiting examples further illustrate the present invention.

EXAMPLES
lo The materials employed below were obtained from Aldrich Chemical Co.
(Milwaukee, WI) unless otherwise specified.
The following F.Y~mples illustrate the formation of spacers on a glass substrate using the following process. The spacers were formed on a glass substrate by placing the coated side of the therrnal l,~,srer donor element in intim~te contact with the glass substrate in a recessed vacuum frame and then imaged using a single mode Nd:YAG laser in a flat field scA~ "g configuration.
The laser was inrident upon the substrate side of the thermal l,all~rer rlrmrnt and normal to the l,u,~rer elc~ /glass receptor surface. Sc~nning was done with a linear galvonometer focused on to the image plane using an f-theta scan lens. The power on the image plane was 8 watts and the laser spot size (measured at the 1/e2 intensity) was 140 x 150 microns. The linear laser spot velocity was 4.6 meterslsecond measured at the image plane.

Exam~le 1 A carbon black light-to-heat conversion layer was prepared by coating the following LTNC Coafing Solution 1 onto a 0.1 mm (3.88 mil) PET substrate with a #9 coating rod.

CA 022~7224 1998-12-02 W O 97/50016 PCTrUS96/16943 LTHC Coatin~ Solution 1:
Component Parts by Weit!ht Raven 760 Ultra carbon black pigment3.78 (available from Columbian Chemicals, Atlanta, GA) Butvar B-98 (polyvinyl butyral resin, available 0.67 from Monsanto, St. Louis, MO) Joncryl 67 (acrylic resin, available from S. C. 2.02 Johnson & Son, Racine, Wl) Disperbyk 161 (dispersing aid, available from 0.34 Byk Chemie, Wallingford, CT) FC-430 (fluorochemical surfactant, available 0.01 from 3M, St. Paul, MN) SR 454 (pentaerythritol tetraacrylate available 22.74 from Sartomer, Exton, PA) Duracure 1173 (2-hydroxy-2methyl-1-phenyl- 1.48 l-propanone photoinitiator, available from Ciba-Geigy, Hawthorne, NY) 1 -Methoxy-2-propanol 27.59 Methyl ethyl ketone 41.38 The coating was dried at 80~C for 3 minutes and subsequently W-cured on a 5 Fusion UV Curing Model MC-6RQN fitted with 300 w/inch H-bulbs and utili7:ing a web transport speed of 22.9 m/min. (75 ft./min.) The cured coating had thickness of 3 microns and an optical density of 1.2 at 1064 nm.
Onto the carbon black coating of the light-to-heat conversion layer the Protective Interlayer Solution I was coated using a #4 coating rod.

Protective Interlaver Coating Solution 1:
Component Parts by Wei~ht Neorad NR-440 (50% nonvolatiles in water, 38.00 available from Zeneca Resins, Wilmington, MA) Duracure 1173 1 00 Water 61.00 CA 022~7224 l998-l2-02 W O 97/50016 PCT~US96/16943 The coating was dried at 80~C for 3 minutes and subsequently UV-cured on a Fusion W Curing Model MC-6RQN fitted with 300 w/inch H-bulbs and utilizing a web transport speed of 22.9 m/min. (75 ft/min.). The cured coating had thickness of 1 micron.
s The interlayer was then overcoated with Transferable Spacer Layer Coa~ing Solution I provided below:

ïransferable SpacerLayer Coa~ing~Solution 1:
Component Parts bv Wei~ht Elvacite 2776 (acrylic resin, available from20.00 ICI Acrylics, St. Louis, MO) N,N-dimethylethanolamine 76.00 Water 4 00 o Four separate coatings were made using #4, #6, #8 and #10 wire wound bars and all coatings were dried at 60~C for 3 minutes. The thicknesses of the dried coatings on the four resultant samples ranged from 1 to 2 microns.
The thermal transfer elements were imaged onto 75 mm x 50 mm x 1 mm glass slides using the laser im~ging system described above. The spacer layers 5 were successfully transferred to the glass to give parallel lines approximately 95 microns wide. It was also demonstrated that the thickness of the transferred spacers can be increased by transferring additional spacer layers onto previously ll ~nsr~l l ed spacers to create spacer lines with heights many times the height of the original transferred spacer lines. This was accomplished by repeating the im~ing20 step with additional thermal transfer elements with the positions of the transferring lines registered to the positions of the previously transferred spacers.

Example 2 This example illustrates a thermal transfer element having a composite 25 transferable spacer layer co~ inil-g silica particles with particle spacing dimensions smaller than the thickness of the spacer transfer layer.
A carbon black light-to-heat conversion layer was prepared by coating the following I,THC Coating Solution 2 onto a 0.1 mm (3.88 mil) PET substrate with a Yasui Seiki Lab Coater, Model CAG-150 using a microgravure roll of 228.6 30 helical cells per lineal cm (90 helical cells per lineal inch).

CA 022~7224 1998-12-02 W O 97/50016 PCT~US96/16943 L~C Coa~in~ Solution 2:
ComPonent Parts by Wei~ht Raven 760 Carbon Black pigment 3.78 Butvar B-98 0.67 Joncryl 67 2.02 Disperbyk 161 0 34 FC-430 0.01 SR 351 (trimethylolpropane triacrylate, available22.74 from Sartomer, Exton, PA) Duracure 1173 1.48 1 -Methoxy-2-propanol 27.59 Methyl ethyl ketone 41.38 The coating was in-line dried at 40~C and UV-cured at 6.1 m/min. (20 ft./min.) using a Fusion Systems Model I600 (400 watts/inch) W curing system fitted with H-bulbs. The dried coating had a thickness approximately 3.5 microns and an optical density of 1.2 at 1064 nm.
Onto the carbon black coating of the light-to-heat conversion layer was rotogravure coated Protective Interlayer Coating Solution 2 using the Yasui Seiki Lab Coater, Model CAG-150. This coating was in-line dried (40~C) and UV-cured at 6.1 rn/min. (20 ft/min.) using a Fusion Systems Model 1600 (600 0 watts/inch) W-curing system fitted with H-bulbs. The thickness of the resultant interlayer coating was appr.~;~in.alely 1 ~m. This LITI donor element was denoted as "LITI Donor Element I".
Protective Interlayer Coatin~ Solu~ion 2:
Component Parts bv Wei~ht Butvar B-98 o.gg Joncryl 67 2.97 SR-351 15.84 Daracure 1173 0.99 l-Methoxy-2-propanol 31.68 2-Butanone 47.52 ... ..

CA 022~7224 1998-12-02 wo 97/50016 PCT/USg6/16943 The protective interlayer of LITI Donor Element I was then overcoated with the following Transferable Spacer Layer Coa~ing Solution 2 using a #10 wire wound bar and dried at 60~C for 2 mim~tes The thickness of the dried coating was determined by profilometry to be approximately 2.7 microns.
s Transferable Spacer Layer Coating Solution 2:
Component Parts bv Wei~ht Elvacite 2776 9.62 EMS-American Grilon Primid XL-552 (available o 39 from EMS-American Grilon, Sumter, SC) Nalco Chemical 2327 (40 weight % SiO2 in 25.00 water, available from Nalco Chemicals, Chicago, IL) N, N-dimethylethanolamine 3.96 Water 76.04 The spacer layer (organic binder/SiO2 coating) of the thermal ll~n~l element was placed in intimate contact with a 75 mm x 50 mm x 1 mm glass slide lo receptor and imaged in an imagewise fashion using the procedure described above to transfer spacer lines approxi.llalely 60 microns wide and 2.7 microns thick with a center-to-center spacing of 400 microns. After im~ing, the imaged glass receptor was heated to 250~C in a nitrogen atmosphere for 1 hour to crosslink the spacer lines.
Example 3 This example illustrates a thermal transfer element having a composite ble spacer layer co~ inil~g particles having a spacing dimension greater than the thickness of the tl ~ns~el ~ble spacer layer.
The protective interlayer of LITI Donor Element I in Example 2 was 20 overcoated with Transferable Spacer Layer Coating Solution 3 using the same procedure as described in Example 2 for coating Transferable Spacer Layer Coating Solution 2.

Transferable Spacer l,ayer Coatin~ Solution 3:
Component Parts bv Wei~ht Elvacite 2776 14.42 EMS-American Grilon Primid XL-552 0 58 ZrO2 4-8 micron diameter particles* 5 oo N, N-dimethylethanolamine 4.00 Water 76.00 * Aspreparedinp.~p~ A,F ,~5OfU.S.PatentNo.5,015,373 The spacer layer (organic binder/ZrO2 coating) of the thermal transfer s element was placed in intimate contact with a 75 mm x 50 mm x I mm glass slidereceptor and imaged in an imagewise fashion using the procedure described above to transfer spacer lines applo~ llately 105 microns wide and 3.0 microns thick with a center-to-center spacing of 300 microns. A~er im~ging, the imaged glass receptor was heated to 250~C in a nitrogen atmosphere for 1 hour to crosslink the o spacer lines.

, . .

Claims (10)

What is claimed:
1. A process for selectively placing spacers on a receptor for use in a flat panel display comprising the steps of:
(i) providing a receptor and a thermal transfer donor sheet, said donor sheet comprising in order, (a) a support, (b) a transferable spacer layer, and (c) an optional adhesive layer, wherein at least one of said receptor, said support, said spacer layer or said optional adhesive layer comprises a radiation absorber;
(ii) placing in intimate contact said receptor with said transferable spacer layer of said thermal transfer donor sheet;
(iii) irradiating at least one of said thermal transfer donor sheet or said receptor in an imagewise pattern with imaging radiation, said imaging radiation being absorbed by said radiation absorber and converted to sufficient heat to transfer irradiated areas of said transferable spacer layer of said thermal transfer donor sheet to said receptor;
(iv) transferring said transferable spacer layer in said irradiated areas to said receptor; and (v) removing said thermal transfer donor sheet to form spacer elements corresponding to said irradiated areas on said receptor.
2. A process for selectively placing spacers on a receptor for use in a flat panel display comprising the steps of:
(i) providing a receptor having a first surface and a second surface and a thermal transfer donor sheet, said donor sheet comprising in order, (a) a support, (b) a light to heat conversion layer comprising a first radiation absorber, (c) a transferable spacer layer, and (d) an optional adhesive layer;
(ii) placing in intimate contact said first surface of said receptor with said transferable spacer layer of said thermal transfer donor sheet;
(iii) irradiating at least one of said thermal transfer donor sheet or said receptor in an imagewise pattern with imaging radiation, said imaging radiation being absorbed by said first radiation absorber and converted to sufficient heat to transfer irradiated areas of said transferable spacer layer of said thermal transfer donor sheet to said first surface of said receptor;
(iv) transferring said transferable spacer layer in said irradiated areas to said first surface of said receptor; and (v) removing said thermal transfer donor sheet to form spacer elements corresponding to said irradiated areas on said first surface of said receptor.
3 . The process of Claim 2 wherein at least one of said receptor, said support, said transferable spacer layer or said optional adhesive layer comprises a second radiation absorber which absorbs said imaging radiation.
4. The process of Claim 2 further comprising a non-transferable interlayer interposed between said light to heat conversion layer and said transferable spacer layer of said thermal transfer donor sheet.
5. The process of Claim 4 wherein at least one of said receptor, said support, said non-transferable interlayer or said transferable spacer layer comprises a second radiation absorber which absorbs said imaging radiation and converts said radiation to heat.
6. The process of Claim 2 wherein said receptor further comprises an adhesive topcoat deposited on said first surface.
7. The process of Claim 2 wherein said transferable spacer layer is a composite comprising particles having spacing dimensions less than the thicknessof said spacer layer.
8. The process of Claim 2 wherein said transferable spacer layer is a composite comprising particles having a mean spacing dimension greater than the thickness of said spacer layer.
9. The process of Claim 2 further comprising the steps of:
(vi) attaching said spacer elements to a substrate to form cavities between said substrate and said receptor;
(vii) filling said cavities with liquid crystal materials; and (viii) sealing the periphery of said substrate to said receptor.
10. A thermal transfer donor sheet suitable for use in selectively placing spacers on a receptor in a flat panel display comprising:
(i) a support, (ii) a light to heat conversion layer comprising a first radiation absorber which absorbs a first portion of imaging radiation and converts said first portion of imaging radiation to heat, (iii) a transferable spacer layer comprising a composite of particles dispersed in a binder, said particles having a mean spacing dimension greater than the thickness of said transferable spacer layer, and (iv) an optional adhesive layer.
CA 2257224 1996-06-27 1996-10-23 Process and materials for imagewise placement of uniform spacers in flat panel displays Abandoned CA2257224A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US08/671,283 1996-06-27
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US5710097A (en) 1998-01-20
EP1015938A1 (en) 2000-07-05
AU7467796A (en) 1998-01-14
TW531682B (en) 2003-05-11
KR20000022129A (en) 2000-04-25
DE69625527T2 (en) 2003-11-06
ATE230125T1 (en) 2003-01-15
KR100405224B1 (en) 2004-02-05
US5976698A (en) 1999-11-02
MY121675A (en) 2006-02-28
WO1997050016A1 (en) 1997-12-31
EP1015938B1 (en) 2002-12-18
JP2000513826A (en) 2000-10-17
JP3950942B2 (en) 2007-08-01

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