Method for producing flat ribbon structures with continuous extruded fibers for laser phosphor displays
The present disclosure generally relates to micro-ribbon structures used in display systems and methods of fabrication thereof. Individual fibers are made using an extrusion process whereby a core surrounded by an ink portion is extruded to create an individual fiber. The ink portion may include both an inner portion that is in contact with the core and an outer shell portion over the inner portion. The individual fibers are then bonded to adjacent fibers to create micro-ribbon structures. The micro-ribbon structures are of one color and spaced from adjacent micro-ribbon structures of a different color by a light blocking fiber. The micro-ribbon structures are each bonded to the light blocking fiber to create the color stripes used in the display system.
1. A micro-ribbon structure, comprising:
an extruded first fiber having a first ink portion; and
an extruded second fiber having a second ink portion, wherein the first ink portion is bonded to the second ink portion, wherein the first ink portion comprises quantum dots or phosphor material.
2. The micro-ribbon structure of claim 1 , wherein the extruded first fiber comprises a first core portion surrounded by the first ink portion, and wherein the extruded second fiber comprises a second core portion surrounded by the second ink portion.
3. The micro-ribbon structure of claim 2 , wherein the first ink portion includes a first inner portion contacting the first core portion and a first shell portion surrounding the first inner portion, and wherein the second ink portion includes a second inner portion contacting the second core portion and a second shell portion surrounding the second inner portion.
4. The micro-ribbon structure of claim 2 , wherein the first core portion comprises glass, metal, or polymer.
5. The micro-ribbon structure of claim 3 , wherein the first shell portion is bonded to the second shell portion.
6. The micro-ribbon structure of claim 1 , further comprising an extruded light blocking fiber having a blocking core and a blocking ink portion, wherein the blocking ink portion is bonded to the second ink portion.
7. The micro-ribbon structure of claim 6 , wherein the extruded first fiber has first diameter, wherein the extruded light blocking fiber has a blocking diameter, and wherein the first diameter and the blocking diameter are different.
8. The micro-ribbon structure of claim 7 , wherein the first diameter is greater than the blocking diameter.
9. The micro-ribbon structure of claim 6 , wherein the first ink portion has a first diameter, wherein the blocking ink portion has a blocking ink diameter, and wherein the first diameter and the blocking ink diameter are different.
10. The micro-ribbon structure of claim 9 , wherein the first diameter is greater than the blocking ink diameter.
11. The micro-ribbon structure of claim 9 , wherein the first diameter is less than the blocking ink diameter.
12. A micro-ribbon structure, comprising:
an extruded first fiber having a first ink portion; and
an extruded second fiber having a second ink portion, wherein the first ink portion is bonded to the second ink portion, wherein the first ink portion is bonded to the second ink portion by a light blocking adhesive.
13. A display apparatus comprising a micro-ribbon structure, wherein the micro-ribbon structure is a first micro-ribbon structure, wherein the micro-ribbon structure comprises:
an extruded first fiber having a first ink portion; and
an extruded second fiber having a second ink portion, wherein the first ink portion is bonded to the second ink portion.
14. The display apparatus of claim 13 , further comprising a second micro-ribbon structure comprising:
an extruded third fiber having a third ink portion.
15. The display apparatus of claim 14 , further comprising an extruded fourth fiber having a fourth ink portion, wherein the third ink portion is bonded to the fourth ink portion, wherein the first ink portion and the second ink portion comprise a first color, wherein the third ink portion and the fourth ink portion comprise a second color, and wherein the first color is different from the second color.
16. The display apparatus of claim 14 , further comprising a light blocking fiber having a light blocking ink portion, wherein the first ink portion and the third ink portion are each bonded to the light blocking ink portion.
17. The display apparatus of claim 16 , further comprising a first pressure sensitive adhesive, wherein the first micro-ribbon structure, the second micro-ribbon structure, and the light blocking fiber are sandwiched between the first pressure sensitive adhesive and an anti-glare hard coating.
18. The display apparatus of claim 17 , wherein the light blocking fiber is in contact with the first pressure sensitive adhesive, and wherein the first micro-ribbon structure and the second micro-ribbon structure are each spaced from the first pressure sensitive adhesive by air gaps.
19. A method of manufacturing a micro-ribbon structure, comprising:
extruding a first micro-ribbon, wherein the first micro-ribbon comprises a first ink portion, wherein the first ink portion comprises a first inner portion and a first outer portion; and
extruding a second micro-ribbon, wherein the second micro-ribbon comprises a second ink portion, wherein the second ink portion comprises a second inner portion and a second outer portion, wherein the first ink portion and the first outer portion are extruded in parallel.
20. The method of claim 19 , further comprising bonding the first micro-ribbon to the second micro-ribbon.
21. The method of claim 20 , wherein the bonding comprises:
aligning the first micro-ribbon and the second micro-ribbon under heat, wherein the heat is at a temperature above a melting point of the first outer portion and the second outer portion; and
cooling the first micro-ribbon and the second micro-ribbon.
22. The method of claim 20 , wherein the bonding comprises:
aligning the first micro-ribbon and the second micro-ribbon; and
exposing the first micro-ribbon and the second micro-ribbon to UV light to cure the first micro-ribbon and the second micro-ribbon.