Micro-fastened, sealed light modulator

1. A switchable light modulator device comprising a fluid layer disposed between opposite spaced apart major surfaces of first and second substrates, each of said substrates having first and second interoperable microstructures formed on said opposite major surfaces, said respective microstructures fitting together to join said first and second substrates and to define wall portions for a plurality of cavities, said cavities sealing said fluid in discrete volumes, wherein said second microstructures define said wall portions and comprise an elastomeric solid polymer characterized by a glass transition temperature less than 20 degrees Celsius and possessing crosslinks.

2. A device according to claim 1 wherein said first and second microstructures are arranged to press fit together.

3. A device according to claim 1 wherein said interoperable microstructures have a repeating pattern in one or both axes of said major surfaces and wherein said microstructures of one pattern instance are interchangeable with those of another.

4. A switchable light modulator device comprising a fluid layer disposed between opposite spaced apart major surfaces of first and second substrates, each of said substrates having first and second interoperable microstructures formed on said opposite major surfaces, said respective microstructures fitting together to join said first and second substrates and to define wall portions for a plurality of cavities, said cavities sealing said fluid in discrete volumes, wherein said first and second microstructures are arranged to press fit together and wherein said first and second microstructures are arranged to have interference when press fitted, and said first or second microstructures provide an opening into which the other fits, and the interference fit lies in the range from 0.5% to 7.5% of the opening width or diameter.

5. A switchable light modulator device comprising a fluid layer disposed between opposite spaced apart major surfaces of first and second substrates, each of said substrates having first and second interoperable microstructures formed on said opposite major surfaces, said respective microstructures fitting together to join said first and second substrates and to define wall portions for a plurality of cavities, said cavities sealing said fluid in discrete volumes, wherein said first and second microstructures are arranged to press fit together and wherein said cavities' wall portions are under load established during press fitting, and cavities are characterized by a wall height that corresponds to the cell gap of said fluid layer and that is less than the wall height before said press fitting by at least a factor of 0.99, and said microstructures provide a hard stop defining said wall loading.

6. A device according to claim 1 wherein said cavities' seals are between said wall portions and said major faces and/or between respective first and second wall portions on said first and second microstructures.

7. A device according to claim 2 wherein said microstructures are arranged to force said fluid out from between said first and second interoperable microstructures by said press fitting.

8. A device according to claim 1 wherein said joining and sealing is enhanced by polymerization of said microstructures once joined, the polymerization providing covalent bonds in said joints and seals.

9. A device according to claim 2 wherein said joints between said microstructures, established during said press fit, micro-fasten said substrates to each other and resist separation due to the sum of counter forces comprising one or more of: friction provided by said joints, suction provided by loading of said cavities' wall portions, and the surface tension of said fluid and the adhesion of said fluid to the interface surfaces of said cavities.

10. A device according to claim 2 wherein said microstructures define one or more openings enabling an excess of said fluid to be forced from said cavities during said press fitting.

11. A device according to claim 1 wherein at least one of said substrates comprises a flexible material.

12. A device according to claim 1 wherein a minority of microstructures are present to align said first and second substrates and these have a greater engagement length than the majority.

13. A device according to claim 1 wherein said microstructures form a quasi-random pattern on said substrates that repeats over a fixed distance across the viewing face of said device or is embedded in a grid pattern across said viewing face.

14. A device according to claim 1 wherein each of said first and second interoperating microstructures comprise either: a plate and a wall, an arm and a wall, a post and a discontinuous hole, a post and a wall, a post and a discontinuous annulus, a discontinuous annulus plug and corresponding discontinuous annulus and post, a cantilever and a mating discontinuous recess, or a key and a slot.

15. A device according to claim 1 wherein said microstructures comprise filleted or chamfered heads, and a head of said microstructures is thinner than a base by at least a factor of 0.85.

16. A device according to claim 1 wherein an engagement length along a length of interoperating first and second microstructures is from one tenth to ten tenths of the cell gap of said fluid layer.

17. A device according to claim 1 wherein said switchable light modulator device is one of the following types, or hybrid versions thereof: an electrophoretic device, a liquid crystal device, a suspended particle device, an electro-wetting device, an electrokinetic device, an electrochromic device incorporating an electrolytic fluid gel, a thermochromic device, or a photochromic device.

18. A device according to claim 1 wherein said device's substrates are flexible glass having a thickness less than 200 microns.

19. A method of forming the device according to claim 1 comprising laminating said device's substrates and fluid between a pair of NIP rollers with the substrates held under tension.