PROCESSES FOR THE PRODUCTION OF ELECTROPHORETIC

DISPLAYS

[Para 1] This application is related to International Application No.PCT7US2004/009421 (Publication No. WO 2004/088002), to which the reader is referred for the state of the art relating to this invention, including definitions of the terms "electro-optic", "bistable" and

"Instability".

[Para 2] This invention relates to processes for the production of electrophoretic displays. [Para 3] One major reason why encapsulated electrophoretic displays can be produced inexpensively by printing processes is that the electrophoretic medium itself has substantial mechanical strength and cohesion; so that the display medium itself be printed. Also, the mechanical strength and cohesion of an electrophoretic medium can maintain desired spacing between electrodes disposed on either side of the medium without any need for mechanical spacers or similar devices. Accordingly, if the electrodes (and any substrates attached thereto) are flexible, the encapsulated electrophoretic display can be curved or rolled without affecting the display qualities of the device; see, for example, Drzaic et al, A Printed and Rollable Bistable Electronic Display SID (Society for Information Display) 98 Digest, page 1131 (1998), which illustrates a flexible encapsulated electrophoretic display being rolled around a pencil without damage.

[Para 4] Furthermore, because of the mechanical strength and cohesion of the electrophoretic medium, such a medium can in principle be applied to any substrate on which an electrode can be provided; for example, the substrate could have an arbitrary three-dimensional shape, as opposed to an essentially laminar sheet which is curved in one dimension. Techniques such as sputtering may be used to apply electrodes to arbitrary three- dimensional shapes, but prior art techniques for applying an electrophoretic medium to such arbitrary shapes leave a great deal to be desired, especially given the need for careful control of the deposition of such a medium to produce optimum optical performance. [Para 5] Display performance (e.g., its optical performance) and visual appeal (i.e., minimizing visual defects) depends critically on obtaining a high quality coating, that is coatings are preferably of uniform thickness (often a monolayer of capsules is desirable), and contain a high areal density of capsules with a minimum of defects. For example, regions where capsules are not in contact with the electrode or where the surface density of capsules varies laterally with respect to the substrate, or where the coating thickness varies,

show up as a degraded dark or white states, non-uniformity in the optical state or graininess, or as non-uniformities during switching respectively. Certain of the E Ink and MIT patents mentioned in WO 2004/088002 describe the use of a metered slot coating technique to produce monolayer capsule coatings and lamination adhesive coatings suitable for use in commercial products.

[Para 6] However, as already mentioned these prior art techniques are not satisfactory for forming, on arbitrary three-dimensional shapes, electrophoretic medium coatings with a sufficiently uniform thickness to give optimum optical performance. While coating methods such as dip or spray coating can be applied to arbitrary three-dimensional shapes, it is difficult to or impossible to achieve uniform capsule monolayers over the substrate surface using these coating techniques. [Para 7] Other problems encountered with slot coating techniques include:

(a) chatter-like streaks parallel to the coating head (for example, due to vibrations in the coating apparatus); these streaks are believed to result from periodic bunching or jamming of capsules;

(b) streaking in the direction of coating (i.e., perpendicular to the slot of the coating head), believed to be due to capsule jamming or non-uniform flows in delivery of capsules to the coating head;

(c) less than desirable capsule contact (or wetting) with the optical face due to inadequate settling or deformability of the small capsules (of the order of 20-200 μm) typically used in encapsulated electrophoretic displays; and

(d) non-uniformities in coating thickness due to formation of multiple layers of capsules (see WO 00/20922 for a discussion of the advantages of forming only a single layer of capsules on a substrate).

The presence of these types of defects can adversely affect the appearance and optical performance of the display.

[Para 8] Also, some of the of the E Ink and MIT patents mentioned in WO 2004/088002 (see especially WO 00/03291) describe displays in which more than one type of capsule is used, the plurality of types of capsules being arranged in a predetermined pattern on a substrate. For example, a full color display could make use of three different types of capsules, say white/red, white/green and white/blue arranged in stripes of triads; such a display could achieve full color without requiring a color filter of the type used in full color

liquid crystal displays. However, while conventional printing techniques might be used to prepare large displays of this type having resolutions of (say) less than 10 lines per inch (approximately 0.4 lines per mm), producing high resolution displays of this type with resolutions of about 100 lines per inch (approximately 4 lines per mm) with such conventional techniques is very difficult. Again, while spray or ink jet coating might be used to apply the patterned coatings of capsules, producing monolayer capsule coatings using these methods will be difficult or impossible.

[Para 9] Improved methods for achieving patterned deposition of encapsulated electrophoretic media would facilitate several applications of electrophoretic displays that are presently difficult or impossible to achieve. Also, improved patterned deposition of electrophoretic media could improve the properties of several kinds of displays presently made by other processes. For example, spot-color displays can be made by superposing a colored film on top of a monochrome (black and white) display. If the backplane driving the display is appropriately segmented and connected to appropriate electronics, the part of the monochrome display under the colored film can be driven separately from the rest of the display so as to produce an area of color in addition to monochrome information. The colored film must be registered with the backplane, and the displayed color can only be that of the film, plus black. Switching between two colors (red plus blue, for example) is not possible in this type of display. Patterned electrophoretic medium deposition would allow deposition of media of arbitrary colors and color combinations. Media deposition registered with backplane segments would obviate the registration step, and could be used to provide high resolution flexible color applications.

[Para 10] Full color displays require separate addressing of (typically) three or four differently colored sub-pixels. Most prior art full color electrophoretic displays have used a registered color filter array superposed on a monochrome display driven by an active matrix backplane. An alternative way of achieving a full color electrophoretic display would be to use the same backplane with a patterned array of electrophoretic media containing appropriate sets of electrophoretic particles (most commonly, red plus black, green plus black, blue plus black, and optionally white plus black). Using multiple electrophoretic media in this way has several advantages in the construction of highly flexible full color displays, including avoiding difficulties in registration, especially registration when the display is flexed.

[Para 11] The present invention seeks to provide processes for the production of electrophoretic displays, and in particular for processes for depositing capsules on a substrate, which reduce or eliminate the problems of the prior art processes for depositing capsules described above. Some processes of the present invention can be used to produce full color displays. The present invention also provides apparatus for use in this process. [Para 12] Accordingly, this invention provides apparatus for forming a coating of an encapsulated electrophoretic medium on a substrate comprising a conductive layer. This apparatus comprises: a coating die having walls defining an aperture and means for supplying a fluid form of the encapsulated electrophoretic medium to the aperture; transport means for moving the substrate in one direction past the coating die; an electrode arranged adjacent the aperture in the coating die such that the substrate passes the electrode after having passed the coating die; and voltage supply means arranged to apply a voltage between the electrode and the conductive layer of the substrate.

[Para 13] In the apparatus of this invention, the voltage supply means is arranged to vary the voltage applied between the electrode and the conductive layer. The voltage supply means may be arranged to vary cyclically the voltage applied between the electrode and the conductive layer.

[Para 14] The term "conductive portion" of the substrate, as used herein, is not to be construed as requiring a degree of conductivity such as that normally associated with metals. The currents involved in the electrophoretic deposition of capsules are so low that many materials normally thought of as semiconductors, or even some insulators, have sufficient conductivity to function as the conductive portion of the substrate in the present process. Whether a given material has sufficient conductivity can readily be determined empirically; however, typically this is not an issue, since as described in detail below, the present invention will normally be practiced by depositing the capsules on to one electrode (which may be formed, for example, from a metal layer, a conductive polymer or a conductive metal oxide) of the final display, and such an electrode will necessarily have sufficient conductivity to function in the present process.

[Para 15] As in the aforementioned WO 2004/088002,the present process may include depositing a polymeric binder and/or a lamination adhesive on the substrate. The capsule- containing fluid may be an aqueous fluid; since the capsule deposition process is typically sensitive to pH, the fluid may contain a buffer to control its pH. The fluid/capsule mixture may have a conductivity of at least about 10 μS/cm. Considerably higher conductivities, for example at least 1 mS/cm., may be useful.

[Para 16] The apparatus of the present invention may comprise optical detection means for detecting markings on the substrate, and the voltage supply means may be arranged to vary the voltage applied between the electrode and the conductive layer in dependence upon the position of the markings detected by the optical detection means.

[Para 17] In this apparatus, the electrode will typically have a width, measured perpendicular to the direction of movement of the substrate, at least twice as great as its length, measured parallel to the direction of movement of the substrate. The width to length ratio may be much greater than two; as explained below, the length of the electrode should be kept as small as possible so that the apparatus can produce narrow stripes of the electrophoretic medium such as are needed in high resolution color displays (typically in excess of 100 lines per inch, or about 4 lines per mm), whereas the electrode may have a width equal to the web on which the electrophoretic medium is being coated, and such webs will typically be 300 mm or more in width.

[Para 18] This invention also provides a process for forming a coating of an encapsulated electrophoretic medium on a substrate comprising a conductive layer, the process comprising: contacting the substrate with a fluid form of the encapsulated electrophoretic medium; and while the substrate is in contact with the fluid form, moving the substrate past an electrode while applying a voltage between the electrode and the conductive layer of the substrate, the voltage being varied with time such that the electrophoretic medium is deposited on a plurality of discrete areas of the substrate, these discrete areas being separated by areas in which electrophoretic medium is not deposited on the substrate. [Para 19] In this process, after deposition of the electrophoretic medium on discrete areas of the substrate, the substrate may be washed to remove electrophoretic medium therefrom. The electrophoretic medium may also be cured (a term which is used herein to cover drying,

cross-linking or any other method used to convert fluid versions of electrophoretic media to solid versions thereof) after washing. As noted above, the electrode will typically have a width, measured perpendicular to the direction of movement of the substrate, at least twice as great as its length, measured parallel to the direction of movement of the substrate; the width to length ratio may be much greater than two. The substrate may be provided with markings, and the process may include detecting these markings and using the detection of the markings to control the variation of the voltage applied between the electrode and the conductive layer of the substrate. The markings may have the form of a plurality of spaced bars extending substantially perpendicular to the direction of movement of the substrate. [Para 20] Certain variants of the process of the present invention are especially useful for forming color displays comprising multiple types of electrophoretic medium. For example, in one such variant of the present process, after deposition of the electrophoretic medium on discrete areas of the substrate, non-deposited electrophoretic medium is removed from the substrate, and the substrate is then contacted with a fluid form of a second encapsulated electrophoretic medium. While the substrate is in contact with the fluid form of the second encapsulated electrophoretic medium, the substrate is moved past an electrode while a voltage is applied between the electrode and the conductive layer of the substrate, this voltage being varied with time such that the second electrophoretic medium is deposited on a plurality of discrete areas of the substrate not occupied by the previously-deposited ("first") electrophoretic medium. The plurality of discrete areas of the substrate on which the first electrophoretic medium is present may have the form of stripes extending perpendicular to the direction of movement of the substrate, and the second electrophoretic medium may be deposited as a series of stripes substantially parallel to but spaced from the stripes of the first electrophoretic medium. Alternatively, if the plurality of discrete areas of the substrate, on which the first electrophoretic medium is present, have the form of stripes extending perpendicular to the direction of movement of the substrate, the movement of the substrate during contact with the fluid form of the second electrophoretic medium may be substantially parallel to the stripes of the first-deposited electrophoretic medium, so that the second electrophoretic medium is deposited as a series of broken stripes running substantially perpendicular to the stripes of the first electrophoretic medium. In any event, after deposition of the second electrophoretic medium on the substrate, non-deposited second electrophoretic medium may be removed from the substrate, and the substrate

contacted with a fluid form of a third encapsulated electrophoretic medium, thereby depositing the third electrophoretic medium on areas of the substrate not occupied by the first and second electrophoretic media. While the substrate is in contact with the fluid form of the third encapsulated electrophoretic medium, the substrate may be moved past an electrode while applying a voltage between the electrode and the conductive layer of the substrate, the voltage being varied with time such that the third electrophoretic medium is deposited on areas of the substrate not occupied by the first and second electrophoretic media. For example, the three electrophoretic media may be deposited as a series of cyclically repeating parallel stripes. Alternatively, in the previously-discussed variant, in which the plurality of discrete areas of the substrate on which the first electrophoretic medium is present have the form of stripes extending perpendicular to the direction of movement of the substrate, and the second electrophoretic medium is deposited as a series of broken stripes running substantially perpendicular to the stripes of the first electrophoretic medium, the third electrophoretic medium may be deposited on substantially all areas of the substrate not occupied by the first and second electrophoretic media. [Para 21] In all variants of the present invention, the substrate may comprise a light- transmissive polymeric film and a light-transmissive conductive layer. After deposition of the encapsulated electrophoretic medium the substrate/electrophoretic medium sub- assembly thus produced may be laminated to a second sub-assembly comprising a lamination adhesive layer and a release sheet, with the lamination adhesive layer being laminated to the electrophoretic medium, thus forming a front plane laminate as described in WO 03/104884.

[Para 22] The invention extends to an electrophoretic display produced a process of the present invention. Such displays of the present invention may be used in any application in which prior art electro-optic displays have been used. Thus, for example, the present displays may be used in electronic book readers, portable computers, tablet computers, cellular telephones, smart cards, signs, watches, shelf labels and flash drives. [Para 23] Figure 1 is a schematic side elevation of a slot coating apparatus adapted for use in the process of the present invention.

[Para 24] Figures 2A-2D illustrate various templates which can be used to control the deposition of multiple types of capsules on a substrate in accordance with a preferred variant of the process of the present invention.

[Para 25] Figures 3A and 3B illustrate the two extreme optical states of a substrate coated with an ordered arrangement of three different types of capsules in accordance with a second preferred variant of the present invention.

[Para 26] Figure 4 illustrates the geometric layout of a preferred color pixel comprising three differently colored sub-pixels, this color pixel being capable of being produced by a process similar to that used to produce the coated substrate shown in Figures 3A and 3B. [Para 27] Figure 5 illustrates the pixel arrangement of part of a display which can be produced from multiple copies of the pixel shown in Figure 4.

[Para 28] As already mentioned, this invention provides a process for forming a coating of an encapsulated electrophoretic medium on a substrate. In this process, there are dispersed in a fluid a plurality of capsules, each of which comprises a capsule wall, a fluid encapsulated within the capsule wall and a plurality of electrically charged particles disposed in the fluid and capable of moving therethrough on application of an electric field to the capsule. A conductive portion of a substrate is contacted with the fluid, and a potential difference is applied between this conductive portion of the substrate and a counter- electrode in electrical contact with the fluid.

[Para 29] Typically, in the present process, a limited quantity of capsule-containing fluid is placed on the substrate, typically by slot coating, although other coating techniques such as curtain coating or spray coating may be employed, and the application of the potential difference serves to deposit the capsules from this limited quantity of fluid; in many cases, substantially all the capsules present in the limited quantity of fluid will be deposited on the substrate.

[Para 30] The preparation of a complete electrophoretic display may of course involve more steps than the electrophoretic deposition process of the present invention. The complete process may include pre-treatment of the surface to improve adhesion of capsules and/or other components to the substrate. The complete process may include simultaneous or sequential coating of two or more components of the display, for example a binder (which surrounds the capsules to form a coherent electrophoretic layer) and a lamination adhesive. In particular, it is generally advantageous to deposit both the capsules and the binder by the electro-deposition process of the invention, and typically these two components may be deposited simultaneously. The lamination adhesive, if deposited by electro-deposition, will typically be deposited in a separate step from the capsules. The

binder and/or adhesive may be polyurethane latex dispersions; however, other charged polymeric latices, charged soluble polymers developed for improved material and performance properties (for example reduced humidity sensitivity, better mechanical integrity, better adhesion, etc.) could also be used as surface pre-treatments, binders and adhesives in the present process. In addition, it may be possible to use uncharged components for surface pre-treatments or binders with an electrophoretic deposition process, where say physical adsorption to either the surface or charged capsules prior to electrophoretic deposition incorporates this component into the electro-deposited layer, and allows it to serve a purpose such as enhancing binding or adhesion.

[Para 31] This invention also provides compositions and deposition conditions that enable production of coatings with desirable properties. As already noted, typically a desirable coating consists of a monolayer of capsules, with a high capsule surface area coverage (optimally 100%; however, many factors, such as the thickness of the capsule wall, presence of binder, and defects, reduce coating coverage) of the coated electrode substrate, good capsule-capsule and capsule-substrate contact or wetting. It is also desirable that the coating thickness be uniform over the coated area, that capsules be coated only on the target portions of the substrate, and that capsules be coated with a minimum of binder. Other aspects of desirable coatings are that any damage to the coated electrode substrate, say by electrochemical degradation during deposition, be minimized by appropriate choice of formulation and deposition conditions, that the coating exhibit good wet adhesion to the particular substrate being coated. In accordance with preferred embodiments of the present invention, compositions and deposition conditions may be optimized to produce a desirable coating on a particular conductive substrate, for example, copper, platinum, gold, or indium tin oxide. This invention allows preparation of very thin (much less than 10 μm), uniform coatings of lamination adhesive, coatings which are not easily prepared with prior art machine coating processes and which, by means of the present process, may be applied directly onto a capsule layer coating.

[Para 32] As already mentioned, typically only a limited quantity of capsule-containing fluid is placed on the substrate. In a preferred form of the process, the placement of the limited quantity of fluid is effected by slot coating, hence producing what may be termed a "slot coating electrophoretic capsule deposition process" or "SCECD process. The present process will hereinafter be described principally with regard to its SCECD form, since it is

believed that the necessary modifications to adapt the process to the use of other methods for depositing a limited quantity of capsule-containing fluid on to a substrate will readily be apparent to those skilled in coating technology.

[Para 33] A preferred form of the SCECD process will now be described with reference to Figure 1 of the accompanying drawings, which is a schematic side elevation of a slot coating apparatus of the present invention (generally designated 200) including a coating die 202 through which a mixture of capsules 204 and a binder 206 is coated on a substrate 208, which is moving relative to the die 202 from right to left as illustrated in Figure 1, as indicated by the arrow. As in the prior art processes, the substrate 208 comprises a polymeric film bearing on its upper surface (as illustrated in Figure 1) a conductive layer, but for ease of illustration this conductive layer is not shown separately in Figure 1. A battery 210 applies voltage between a negative electrode 212, built into the die 202, and the conductive layer of the substrate 208, so that the capsules 204 and the binder 206 are electrophoretically deposited on to the conductive layer of the substrate 208 while the substrate is adjacent the electrode 212, the process being terminated locally as the upper face of the substrate 208 exits the coating head and is exposed to air.

[Para 34] The present process can be used to deposit capsules in controlled areas of an unpatterned electrode. The multi-step processes described in the aforementioned WO 2004/088002, in which different types of capsules are deposited upon different set of electrodes on a substrate, have the disadvantage that the capsules are necessarily deposited upon the pixel electrodes. In contrast, when forming an electrophoretic display in which the capsules are sandwiched between a backplane containing a matrix of pixel electrodes and a front substrate having a single continuous electrode extending across a large number of pixels and typically the whole display (this front substrate forming the viewing surface of the display), it is normally preferred to deposit the capsules on the continuous electrode. Coating microcapsules on to the substrate which forms the viewing surface of the display is advantageous because as the coating dries capsules can be made to flatten against the substrate and wet neighboring capsules to improve packing and increase the optical density of the coating, thereby generally improving the optical performance of the display. The exposed back surface of the coating has a roughness of several microns and capsules pucker and deform to compensate for the flattening and wetting occurring at the continuous electrode. In contrast, when a transparent electrode is laminated with a thin layer of

adhesive to a capsule coating produced on the pixel electrodes, the electro-optic performance as measured from the rear surface of the capsule/binder coating is somewhat degraded compared to the front side. This degradation may be due to several factors, for example the presence of the adhesive layer in the optical path (this adhesive layer must be at least thicker than the roughness of the capsule layer, so is typically at least 10 μm thick), and/or the roughness and dimpling of the capsules. This degradation may be limited by improving the layer formation process or minimizing the thickness of the adhesive layer. Alternatively, this problem could be avoided completely by constructing a display with transparent transistors present on the front substrate.

[Para 35] Furthermore, as discussed in WO 03/104884, for commercial reasons it is advantageous to form, after capsule deposition, a so-called "front plane laminate" comprising, in order, a light-transmissive electrically-conductive layer, a layer of an electro- optic medium in electrical contact with the electrically-conductive layer, an adhesive layer and a release sheet. Such a front plane laminate can be prepared as a continuous web, cut to size, the release sheet removed and the laminate laminated to a backplane to form a display. Obviously, such a front plane laminate requires that the capsules be deposited upon a continuous front electrode.

[Para 36] Thus, both from the point of view of maximizing the electro-optical performance of a display and from the point of view of commercial manufacturing convenience, it is advantageous to effect patterned deposition of capsules on to a continuous front plane electrode, and then align the resultant patterned electrode with the back plane containing a matrix of pixel electrodes. This invention provides such a modified capsule deposition process wherein the length scale defining the pattern is smaller than that describing the lateral size of the electrode surface on which the capsules are deposited. [Para 37] It has been found that patterning of capsules on a substrate can be controlled by varying the voltage applied between an electrode (such as the electrode 212 shown in Figure 1) and the substrate, as the substrate is being moved relative to the electrode. (It will be appreciated that only relative movement between the substrate and the electrode affects the coating operation, and which one of the substrate and electrode actually moves, or if both move, is a matter of engineering design. Typically, when deposition of capsules is to be effected on a long web, the substrate will be moved past a static coating head. On the other hand, when deposition is to be effected on limited pieces of substrate, it will often be more

convenient to clamp the substrate in a fixed position, and move the coating head, for example by means of one or more threaded rods.)

[Para 38] For example, in apparatus similar to that shown in Figure 1, "stripe deposition" (this term is explained below) of electrophoretic capsules can be achieved by simply turning the voltage between the electrode 212 and the substrate 208 off and on while the conductive substrate is being translated relative to the support. Since capsule deposition occurs only in areas where the current density and field are high, i.e., directly underneath the electrode 212, modulation of the voltage in this way leads to the formation of stripes of deposited capsules, these stripes extending perpendicular to the direction of translation of the substrate and being separated from one another by areas in which no capsules are deposited. The distance between the stripes, and their width, can be controlled by the frequency with which the voltage is modulated, and by the speed of the substrate translation. [Para 39] After the substrate has passed the electrode, the capsules not deposited on the substrate can readily be washed off the substrate surface using a stream of water or by passing the coated substrate through a water bath, or in other ways which will readily be apparent to those skilled in coating technology. Since electrophoretic motion of the capsules will tend to make them move toward areas where deposition is taking place, under carefully controlled conditions (of voltage, substrate speed, voltage modulation frequency, slurry composition, electrode-substrate gap, etc.) capsule waste can be made minimized. [Para 40] Other variables that determine the quality, especially the thickness and uniformity, of the capsule coating are the voltage and the waveform of the voltage pulse applied between the electrode and the substrate. Generally, as the voltage increases, and the substrate translation speed decreases, the number of capsules deposited per unit area initially increases, until deposition of a monolayer of capsules essentially completely covering the desired area of the substrate is achieve. Beyond this voltage/speed combination, capsule multilayers of increasing thickness are formed. For reasons discussed in WO 00/20922, a tightly packed monolayer of capsules is normally desired. Fortunately, there is a substantial barrier to forming multilayers using the electrodeposition technique, so that monolayer coverage is relatively easy to achieve. There is also a minimum voltage below which permanent deposition (i.e., deposition that is not washed off under a gentle stream of water) does not occur; this minimum voltage is best determined empirically for any specific electrophoretic medium and coating apparatus.

[Para 41] To provide well-defined areas of specific electrophoretic media, such as are typically required to ensure that there are no gaps between media and no blending of colors in the final display, it is normally desired that the edges of the stripes be sharp; i.e., that the transition zone between areas of complete monolayer coverage and those of zero coverage be as small as possible. The width of this transition zone can be minimized by appropriately shaping the voltage of the applied voltage pulse. A square wave pulse is generally not preferred, since the zone of deposition of capsules extends somewhat beyond the area directly under the electrode, and, in particular, extends somewhat behind the electrode (relative to the direction of translation), into an area not intended to be covered by the capsules. Since this trailing area will experience a lower field than that present directly under the electrode, and will experience that field for only a short time (since the electrode will rapidly move away from it), it is likely that only partial coverage will occur there. A similar situation will apply at the front of the deposition zone. These areas of partial coverage can be minimized by having the electrical pulse start with a relatively low voltage, increase to a maximum, and then decrease. Because of the existence of a threshold for deposition, the capsules will be drawn toward the area where deposition is desired by the low voltages at the front and back of the zone, but little or no deposition will occur. The use of the shaped pulse therefore both conserves capsules and sharpens the transition zones. The optimal shape of the pulse can be determined empirically.

[Para 42] Since the region of partial deposition will have a length (parallel to substrate translation) similar to the gap between the electrode and the substrate, the use of narrower gaps will give sharper lines and higher coating resolution.

[Para 43] Most applications of patterned capsule deposition require sequential application of different capsules with different internal phases (colors, switching speeds, etc.). One way to achieve sequential application of different capsules is to deposit stripes of a first type of capsules as described above, wash and dry the striped coating, and deposit a second type of capsules using the same process. Because of the threshold for multilayer deposition (particularly in areas covered by a dried layer of capsules), it is possible to apply the second type of capsules in the clear areas between the stripes of the first type of capsules by electrodeposition without modulation of the voltage. However, for more precise deposition, or for the application of more than two different types of capsules, the stripes of the second and subsequent types of capsules must be aligned with the stripes of the first. Physical

alignment of the substrate with the first set of stripes may be possible, but is made more difficult by the fact that the voltage pulses must be timed appropriately so that deposition of the second and later types of capsules occurs only in the desired (clear) areas. [Para 44] The necessary alignment of the various coated areas can be achieved by providing an appropriate template for the coating stripes; this template may be printed (or engraved) directly on the substrate or printed on a separate film which is then secured to the substrate. The template is then used to control the voltage applied between the electrode and the substrate. Since the template is permanently attached to the substrate, and is not removed therefrom during washing, drying (or other curing), remounting of the substrate on the coating apparatus, synchronizing the voltage applied between the electrode and the substrate with the template automatically aligns the various stripes of capsules deposited. The template will primarily be described in the form of an optically-encoded stripe (a barcode), but can be provided in a number of other forms, including a mechanical or electromechanical device (say a sliding contact, one part attached to the substrate, another to the electrode or the coating head used to deposit the capsules), or a magnetically encoded signal detected by a magnetic read head, or any other similar technique.

[Para 45] The template can be a simple series of printed black and white bars, two possible forms of which are illustrated in Figures 2A and 2B; these templates are intended to be attached to the substrate with the bars perpendicular to the direction of translation of the substrate during coating. Figure 2A illustrates regularly spaced bars, with black and white bars of the same width, while Figure 2B illustrates a template in which the black and white bars have differing widths. A light source (e.g., a laser focused to a fine point on the template) is attached to the coating apparatus, together with a sensor (e.g., a photodiode, possibly equipped with a filter to isolate the laser light wavelength) to detect the reflected laser light. As the substrate and template are translated relative to the coating apparatus, the electrical signal generated by the photodiode can be used to gate the voltage applied between the electrode and the substrate. After the first capsule deposition step, washing and drying, the substrate with the template thereon is remounted on the coating apparatus, and the polarity of the signal from the photodiode reversed, so as to control the second capsule deposition step. The substrate must aligned so that the capsule stripes from the first deposition step are perpendicular to the direction of translation of the substrate, i.e., the substrate must travel in the same direction during both capsule deposition steps. The

necessary alignment can be done using mechanical means; for example, an alignment bar, or alignment pins can be provided to mount the substrate on a carrier which moves it past the coating apparatus. However, the spacing of the stripes and their alignment is insensitive to the alignment in the coating direction, and, importantly, to changes in the speed of coating or the frequency of an external waveform generator. This method of controlling capsule deposition may be called "bar-code electrodeposition assisted coating" ("bar-code EDAC", or "BC-EDAC").

[Para 46] Various other methods of bar coding can be used to control deposition of three or more types of capsules. For example, Figure 2C illustrates various gray-scale bar-codes. When using such gray-scale bar codes, the applied voltage is controlled by sensing various output ranges from the photodiode. Figure 2D illustrates a two-bit bar-code using two parallel sets of black and white stripes. Two lasers and/or two photodiodes can be used to control the applied voltage in one of four ways. Several forms of such schemes will be obvious to those skilled in coating technology.

[Para 47] More elaborate patterning of capsules can be effected by using bar-code EDAC with an electrode that is electrically segmented i.e., which is divided into a series of segments insulated from each other so that the voltage between each segment and the substrate can be controlled independently. By coupling information on the bar-code template (giving information about the position of the substrate in a direction parallel to the direction of translation) with electronic control of the various segments of the electrode (giving information about the position in a direction perpendicular to the direction of substrate translation), it is possible to deposit arbitrary patterns of capsules. Full-color displays for attachment to an active matrix backplane could be made in this way, or by simple stripe coating (though stripe coating would require twice as high a resolution), but arbitrary, reprogrammable spot color coating of multiple colors of capsules can be achieved only by such simultaneous control of deposition in two dimensions.

[Para 48] In addition to the bar-coating electrodeposition techniques described above, there are several other ways of using electrodeposition to achieve patterned deposition of capsules for use in electrophoretic displays. For example, a patterned backplane may be used with different segments that can be individually addressed during the electrodeposition step; a segmented printed circuit board (PCB) can be employed in this way. A set of segments is connected together and a voltage may be applied between these segments and a

counter-electrode through a slurry of binder and capsules of a first type. The counter- electrode can be in the form of a coating head that moves relative to the PCB, or a stationary electrode that covers the entire surface of the PCB at one time. After an appropriate time and applied voltage, the counter-electrode is removed, the non-deposited capsules are removed by washing, and the coated PCB dried. Only the segments to which voltage was applied will be coated with deposited capsules and binder. It has been found to be advantageous to interconnect all of the segments that are not being coated in a given step so that they are at the same potential as the counter electrode, since this precaution will diminish unwanted deposition of stray capsules on these segments. A different set of segments can be coated with capsules of a second type by repeating the electrodeposition, washing, and drying steps. This procedure can be repeated an arbitrary number of times limited only by the number of different segments on the PCB.

[Para 49] This approach to patterned deposition has the advantage that no alignment steps are necessary during the preparation of a display. The capsules are automatically deposited only on the segments that will power them during display operation. In principle, this process can be extended to very high-resolution displays, such as those used in an active matrix display. In practice, it is necessary that the display electronics be designed to allow the passage of the required currents and the application of the required voltage across the slurry during the electrodeposition step. Active matrix backplanes and backplane electronics designed simply to drive electrophoretic displays commonly cannot supply the required currents or voltages, so either a separate deposition circuit must be designed into the backplane or the electronics designed differently so as to allow the electrodeposition step(s). [Para 50] It is also possible to use a patterned counter-electrode in a similar way. For example an array of dots of capsules can be prepared by using a counter-electrode in the form of an array of one or more rows of needles. The needles are supported a short distance above an unpatterned conductive substrate in contact with a capsule slurry, or other fluid form of an electrophoretic medium, and a short pulse of current applied between the needles and the substrate. Washing and drying will provide a substrate with an array of capsule dots in register with the needles of the counter-electrode. The counter-electrode can be of essentially any shape, so that any pattern of capsules can be deposited on the conductive substrate. It is desirable that the substrate have the highest possible conductivity, or that the counter-electrode be designed so that portions of it can be powered sequentially, since these

techniques will improve the uniformity of capsule deposition. Alternatively, strips of substrate may be coated sequentially; for example, the substrate may be attached to a cylindrical mandrel, which is rolled across the powered counter-electrode during capsule deposition to improve coating uniformity.

[Para 51] Another variant of the process of the present invention permits deposition of up to three different types of capsules without the complication of providing a bar code on the substrate to control the relative positions of the different types of capsules; this variant allows for deposition of three different types of capsules that involves only a single, very simple alignment, namely a rotation of the substrate by 90° (or some other similar angle) between successive coating operations.

[Para 52] As noted above, spaced stripes of capsules separated by stripes free from capsules can be produced by modulating the voltage applied between an electrode and a conductive substrate as the substrate is translated past the electrode. It has been found that stripes with widths of less than or equal to about 1/16th of an inch (about 1.5 mm), separated by gaps of a similar dimension, can be deposited using a rectified square wave potential applied to the electrode as it is translated relative to the substrate, using a typical prior art capsule slurry and an electrode/substrate coating gap of about 3 mils (about 76 μm). The width of the stripes can be controlled by a number of experimental parameters, including the width of the conductive part of the electrode, the potential between electrode and substrate, the duty cycle of the square wave, its frequency, and the speed of translation. Varying some of these parameters has the expected effects. If the frequency of the square wave is increased, or the translation speed reduced, the stripes become narrower and closer together. As the duty cycle changes to positive (with respect to the substrate) pulses of shorter duration, the stripes become narrower, and the gaps between them wider. The dimensions of the electrode, especially the width of its tip portion in the direction of translation, can influence the width of the stripes, so that for narrow stripes the thinnest possible tip width is desirable. The composition of the coating medium is probably also important in this respect.

[Para 53] As noted above, it has also been found that areas of the substrate on which capsules have already been deposited (especially if the capsules are washed and dried), are very resistant to electrodeposition of a second layer of capsules. For example, as noted above, once one set of stripes has been produced by the voltage modulation process

described above, a second set of stripes of a different color or type from the first can be deposited by electrodeposition without gating the voltage in any way. Thus, uniform stripes of two different capsule types can readily be produced.

[Para 54] It has been found that, if the voltage modulation process described above is repeated with a second type of capsules, but the substrate is rotated by 90° (or a similar angle) between the two coating operations, electrodeposition of the second type of capsules occurs in the form of "broken stripes", i.e., the second type of capsules are not deposited as continuous stripes running at right angles to the stripes of the first type of capsules, but rather as discrete patches between the stripes of the first capsules; the second type of capsules do not deposit in the areas where the stripes of the first capsules are already present. The length (parallel to the long dimension of the first stripes) and frequency of the patches of the second type of capsules are determined by the same consideration as the width of the first stripes (voltage, translation speed, gating frequency, duty cycle, etc.), while the width of the patches (perpendicular to the long dimension of the stripes of the first capsules) is equal to the gaps between the stripes.

[Para 55] After normal washing and drying following the electrodeposition of the second type of capsules, the substrate is left with bare (capsule free) patches having a width equal to that of the gaps between the first stripes and a length equal to the spacing between the patches of the second type of capsules. These bare patches can then be coated with a third type (or color) of capsules by electrodeposition without voltage modulation, thus producing a final substrate being an ordered arrangement of three different types of capsules without requiring the presence of a template on the substrate to control the relative alignment of the three different types of capsules.

[Para 56] Figures 3A and 3B illustrate the two extreme optical states of an experimental display having an electrophoretic medium layer containing three different types of capsules produced in this manner; the experimental display used a backplane comprising only a single electrode so that all the sub-pixels of the display are switched simultaneously; obviously, a commercial display requires a backplane that allows each sub-pixel to be switched independently.

[Para 57] The electrophoretic medium layer of the display shown in Figures 3A and 3B was produced as follows:

(a) spaced stripes of a first encapsulated electrophoretic medium comprising capsules containing a negatively charged yellow pigment and a positively charged black pigment were deposited in a first, voltage modulated electrodeposition step; the resulting continuous stripes 602 extend horizontally as illustrated in Figures 3A and 3B, are black in Figure 3A and yellow (shown as dark gray) in Figure 3B;

(b) after rotating the substrate 90°, broken stripes or patches of a second encapsulated electrophoretic medium comprising capsules containing a negatively charged brown pigment and a positively charged green pigment were deposited in a second, voltage modulated electrodeposition step; the resulting broken stripes 604 extend vertically as illustrated in Figures 3A and 3B, are green (shown as light gray) in Figure 3A and brown (shown as dark gray) in Figure 3B; and

(c) the remaining, essentially rectangular areas of the substrate were coated with a third encapsulated electrophoretic medium comprising capsules containing a negatively charged white pigment and a positively charged black pigment in a third, non- voltage modulated electrodeposition step; the resulting coated areas 606 are black in Figure 3A and white in Figure 3B.

In the two voltage modulated electrodeposition steps, the translation speed was approximately 3 mm sec ^"1 and the gate frequency was about 1 Hz; the operating voltage was 40V (with the substrate positive with respect to the electrode) and the duty cycle was 30 per cent.

[Para 58] The extreme color states of the electrophoretic media used in the experimental display were of course unusual, but similar processes can be carried out using (for example), conventional red/black, green/black, and blue/black (or the corresponding /white) media.

[Para 59] As noted above, a commercial display requires a backplane that allows each sub- pixel to be switched independently, and thus the arrangement of pixel electrodes in the backplane (whether that backplane be of the direct drive type, in which each pixel electrode has a separate conductor by means of which its voltage can be controlled, or of the active matrix type) must conform to the arrangement of color sub-pixels produced by a particular patterning technique. In color electrophoretic media of the type shown in Figures 3A and 3 B, each color pixel has the form shown in Figure 4. As shown in that Figure, the geometry of this pixel may be described as resembling a Greek IT. The cross-bar of the FI comprises a

first sub-pixel 702 of a first color and formed by a section of one of the continuous stripes of the first electrophoretic medium deposited in the first electrodeposition step. If for simplicity one assumes that a square full-color pixel having equal areas of the three different electrophoretic media is desired (and neither of these assumptions is necessarily true) and that the square full-color pixel has an edge length L, the vertical dimension (as drawn in Figure 4) of sub-pixel 702 must be L (since the stripes from which sub-pixel 702 is formed are continuous in one dimension) and its horizontal dimension L/3. Thus, to produce the pixel shown in Figure 4, the first electrodeposition step should be conducted such that the width of the gaps between adjacent stripes is twice the width of the stripes themselves. [Para 60] The color pixel shown in Figure 4 further comprises a second sub-pixel 704 of a second color and formed from one of the patches of the second electrophoretic medium deposited in the second electrodeposition step. Since sub-pixel 704 has a horizontal dimension of 2L/3, equal to the spacing between the stripes of the first electrophoretic medium, its vertical dimension has to be L/2, as shown in Figure 4. Thus, to produce the pixel shown in Figure 4, the second electrodeposition step should be conducted such that the width of the gaps between adjacent patches is equal to the width of the stripes themselves. [Para 61] Finally, the color pixel shown in Figure 4 comprises a third sub-pixel 706 of a third color and formed from the third electrophoretic medium deposited in the third, non- voltage modulated electrodeposition step. The third sub-pixel 706 has the same dimensions as the second sub-pixel 704.

[Para 62] However, the resolution of a display formed from the color pixel shown in Figure 4 is not limited to the resolution (L in both dimensions) of the color pixel itself. As illustrated in Figure 5, by careful choice of size and placement of the pixel electrodes in the backplane, it is possible to produce a display having twice the resolution (i.e., L/2 in both dimensions) of the color pixel itself.

[Para 63] Figure 5 shows two color pixels of the type shown in Figure 4 formed side-by- side. A single backplane pixel comprising sub-pixel electrodes 712, 714 and 716 is illustrated with the sub-pixel electrodes shaded; seven additional adjacent backplane pixels are delimited by broken lines.

[Para 64] As may readily be seen from Figure 5, each backplane pixel is L/2 square, and comprises a first sub-pixel electrode 712 which overlaps one-fourth of the area of the first sub-pixel 702, a second sub-pixel electrode 714 which overlaps one-fourth of the area of the

second sub-pixel 704, and a third sub-pixel electrode 716 which overlaps one- fourth of the area of the third sub-pixel 706. The three sub-pixel electrodes 712, 714 and 716 have the same shapes and orientations as the corresponding sub-pixels 702, 704 and 706 respectively, but are one-half the size so that, as shown in Figure 5, the second sub-pixel electrode 714 covers the lower right quadrant of sub-pixel 704, and the third sub-pixel electrode 716 covers the upper right quadrant of sub-pixel 706, while the first sub-pixel electrode 712 covers part of the first sub-pixel 702 lying in the left-hand half of sub-pixel 702 and extending for a distance L/4 in each direction from the horizontal plane of symmetry of sub- pixel 702.

[Para 65] It should be noted that the pixel electrode immediately below the pixel electrode 712, 714, 716 has its sub-pixel electrodes arranged in the same manner as the sub-pixel electrodes 712, 714 and 716, whereas the pixel electrodes immediately to the left and right of the pixel electrode 712, 714, 716 have their sub-pixel electrodes laterally reversed relative to the sub-pixel electrodes 712, 714 and 716.

[Para 66] Although the process of the present invention has been described above in its application to encapsulated electrophoretic displays, the present process may be useful with other types of electro-optic displays.