MANUFACTURING PROCESS OF SELF-LUMINOUS AND FLEXIBLE FABRIC

Abstract: Disclosed relates to a self-luminous and flexible fabric (EL sheet) used for signboard compring: a upper PVC (11) having a pliability; an ITO electrode layer (12), sputtered on a bottom of the upper PVC (11), having high permeability and conductivity; a phosphor layer (13) formed on bottom of the ITO electrode layer (12); a dielectric layer (14), printed on a bottom of the phosphor layer (13), for inducing electronic luminescence; a conductive mesh (15), laminated on a bottom of the dielectric layer (14), for decreasing electric surface resistance and increasing tension and elasticity of the fabric of large size; and a lower PVC (16), provided on a bottom of the conductive mesh (15), for increasing endurances for humudity. The conductive mesh (15) is composed of polyester fibers (22) on which copper layers (21) and protective layers (23) are coated in turn so as to decrease the electric surface resistance and increase the tension and elasticity of the fabric. Besides, ultraviolet stabilizers can be mixed with the lower PVC (16) so as to increase endurances for ultraviolet ray. In addition, the invention adopts a gravure print process that facilitates the production of the flexible fabric of roll type.

Description: MANUFACTURING PROCESS OF SELF-LUMINOUS AND FLEXIBLE FABRIC Technical Field The present invention relates to a self-luminous and flexible fabric that is used for manufacturing large sized signboards, more particularly, to a self— luminous and flexible fabric of roll type in which a conductive mesh is inserted so as to decrease electric surface resistance and increase tension and elasticity of the fabric. Background Art In the past, conventional signboards have been made using neon signboards or fluorescent lamps as light source, however, the conventional signboard has some drawbacks: first, they should employ high electric power and high voltage; second, their lifetime is very short even though they are very expensive; and they produce environmental contaminants such as mercury, dioxin, etc. when abolished. In case of a conventional EL (electroluminescence) sheet, dedicatedly used for electric and electronic goods, made of PET (polyethylene terephthalate) film and phosphor printed on the PET film, it can be used for such signboards, however, it has a limit of size i.e., maximum 1 m 2 . Besides, when such EL sheet is applied to an outdoor signboard, it meets with difficulties in overcoming some matters such as ultraviolet ray, humidity, waterproof, etc. Besides, with the conventional EL sheet made by silk-screen process, it is very difficult to make the flexible fabric of role type including multi-functions. Disclosure of Invention Accordingly, an object of the present invention is provide a self-luminous and flexible fabric (EL sheet) that emits light with much lower electric power than the conventional EL sheet and can be produced consecutively as a roll type. Another object of the invention is to provide a self-luminous and flexible fabric (EL sheet) that includes a conductive mesh so as to increase tension and elasticity of the fabric. To accomplish an object of the inventions, there is provided A self-luminous and flexible fabric (EL sheet) used for signboard compring: a upper PVC sheet 11 having a flexibility; an ITO electrode layer 12, sputtered on a bottom of the upper PVC sheet 11 , having high permeability and conductivity; a phosphor Iayer13 formed on a bottom of the ITO electrode layer 12; a dielectric layer 14, printed on a bottom of the phosphor layer 13, for inducing electronic luminescence; a conductive mesh 15, laminated on a bottom of the dielectric layer 14, for decreasing electric surface resistance and increasing tension and elasticity of the fabric of large size; and a lower PVC sheet 16, provided on a bottom of the conductive mesh 15, for increasing endurances for ultraviolet ray and humidity. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. Brief Description of Drawings Fig. 1 is a cross section view illustrating a structure of a self-luminous and flexible fabric in accordance with the invention; Fig. 2 shows a structure of a conductive mesh for decreasing electric surface resistance and increasing tension of the fabric in accordance with the invention; and Fig. 3 is an outline describing a manufacturing process of self-luminous and flexible fabric in accordance with the invention. Best Mode for Carrying Out the Invention Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Referring to Figs. 1 and 2, a self-luminous and flexible fabric (EL sheet) comprises a upper PVC (polyvinyl chloride) sheet 1 1 , an ITO (indium tin oxide) layer 12, a phosphor layer 13, a dielectric layer 14, a conductive mesh 15 and a lower PVC sheet 16 in turn. Referring to Fig. 3, there are depicted a feeder 36, a flexible fabric 34, an ink source 33, a cylinder 32, a roller 31 , a drying part 37, and an outlet 36. With the above configuration, the present invention adopts a gravure print process, which can make the flexible fabric of roll type. That is, the upper PVC sheet 1 1 is pressed out about 90 in thickness and the ITO electrode layer 12 is sputtered on the bottom of the PVC sheet 1 1. The ITO electrode layer 12 is made of ITO (indium tin oxide), Sn0 2 , etc. Then, the upper PVC sheet 1 1 sputtered with the ITO electrode layer 12 is inserted into the feeder 36, setting an electric surface resistance about 40~200Ω/sq. Here, if the PVC sheet 11 is not uniformly fed to the feeder 36, the PVC sheet may be sagged or split. Accordingly, it is necessary to rotate a reel rotary axis of the feeder 36 by means of a DC motor so as to feed the PVC sheet 1 1 stably. In the meantime, it is required that the humidity of the workroom where the signboard fabric is produced be maintained pertinently by providing an apparatus for regulating temperature and humidity and the volatility of the materials be kept as well. To print the phosphor layer 13 on the bottom of the PVC sheet 1 1 sputtered with the ITO electrode layer 12, sulfurated zinc (ZnS) phosphor powder is mixed with polymer binder. Here, with the ZnS phosphor powder, activated materials, such as In, Ma, Fe, Mn, Sn, As, P, Cu, etc., and fluoride of rare-earth elements are added. The ZnS phosphor powder and the activated materials are contained in the ink source 33. Here, it is possible to diversify the color of the fabric to be produced by regulating the amount of those materials contained in the ink source 33. After completing the print process as above, the resultant material is dried by hot air of 90-130 °C or by remote infrared light in the drying part 37 to be polymerized, thus forming a solid phosphor layer 13 of 20—30 βn in thickness. Subsequently, dielectric powder (BaTio) mixed with polymer binder of cyanoresin is printed on the bottom of the resultant material 1.2-10 jn thickness two or three times the same manner with the above. After completing the print process as above, the resultant material is dried by hot air of 90— 130°C or by remote infrared light in a drying part 37 to be polymerized, thus forming a dielectric layer 14 of 20-30 in thickness. Then, the conductive mesh 15 is laminated on the resultant material on which the phosphor layer 13 and the dielectric layer 14 are printed in turn on the bottom of the upper PVC sheet 11 sputtered with the transparent ITO electrode layer 12. Here, the conductive mesh 15 applied to the present invention, composed of polyester fibers (22) on which copper layers (21 ) and protective layers (23) of black carbon are coated in turn, is designed to have a density more than 80 lines/per inch to endure the high voltage more than 400 voltage and a electric surface resistance more than 45Ω/sq. Lastly, the lower PVC sheet 16 of sol type is attached to the resultant material. That is, PVC resin is coated in the manner of hot melt so as to strength damp-proofing, which is a defect of the conventional EL sheet. Here, it is possible to add ultraviolet stabilizers to the PVC resin to increase the endurance for the ultraviolet ray. Accordingly, the present invention provides a self-luminous and flexible fabric (EL sheet) having a high brightness and multi-functions produced in the different manners from those of the conventional EL sheet. Industrial Applicability As described above in detail, the present invention provides a self-luminous and flexible fabric (EL sheet) that employs lower electric power and voltage than the conventional fabric, thus saving the electric energy. Besides, the self-luminous and flexible fabric according the present invention can solve the problem of the bad view of city caused by the complicated and intricate outer walls of the buildings on which heavy weight signboards made of the conventional fabric are attached. Moreover, the signboard made of the self-luminous and flexible fabric according to the present invention can be installed on the outer wall of building very simply not only because it is lightweight but also because it doesn't employ any electric wirings and supports, attached to the outer wall, that are necessarily applied to the conventional signboard. In addition, the signboard made of the self-luminous and flexible fabric according to the present invention has a higher brightness and a milder ambiance than the conventional signboard, thus providing the fine view of city that is stabilized more.

Claims: Claims 1 . A self-luminous and flexible fabric used for signboard compring: a upper PVC sheet 11 having a pliability; an ITO electrode layer 12, sputtered on a bottom of the upper PVC sheet 1 1 , having high permeability and conductivity; a phosphor layer 13 formed on a bottom of the ITO electrode layer 12; a dielectric layer 14, printed on a bottom of the phosphor layer 13, for inducing electronic luminescence; a conductive mesh 15, laminated on a bottom of the dielectric layer 14, for decreasing electric surface resistance and increasing tension and elasticity of the fabric of large size; and a lower PVC sheet 16, provided on a bottom of the conductive mesh 15, for increasing endurances for humidity. 2. The self-luminous and flexible fabric as recited in claim 1 , wherein the conductive mesh 15 is composed of polyester fibers 22 on which copper layers 21 and protective layers 23 are coated in turn. 3. The self-luminous and flexible fabric as recited in claim 1 , wherein the lower PVC sheet 16 includes ultraviolet stabilizers to increase endurances for ultraviolet ray.

Inventors: DAN CHUNGU, DAN, CHUNGU
Applicants: DAN CHUNGU, GAKOREATECH, DAN, CHUNGU
Application year: 2001
Main classification: H05B33
IPC codes: H05B33