Method for making an electroluminescent panel lamp as well as panel lamp produced thereby

Claim 2

Apparatus for making an electroluminescent panel comprising: first dielectric depositing means for depositing a first dielectric layer on a conductive layer of a carrier strip moving therepast, wherein said first dielectric depositing means is of the rotogravure type and said second dielectric depositing means is a knife-over roller depositor; means for depositing a mono-layer of phosphor particulate on said first dielectric layer as said carrier strip moves therepast wherein said phosphor particulate mono-layer has a thickness no greater than the largest phosphor particle deposited in said phosphor particulate mono-layer; first radiation curing means adjacent said carrier strip and located intermediate said phosphor particulate mono-layer depositing means and said second dielectric depositing means; second dielectric depositing means for depositing a second dielectric layer on said phosphor particulate mono-layer as said carrier strip moves therepast, and means for moving said carrier strip past each of said first dielectric, said phosphor particulate mono-layer and said second dielectric depositing means, respectively.

Claim 3

The apparatus of claim 1 further including means for vapor depositing a reflective, electrically conductive layer on said second dielectric layer as said carrier strip moves therepast.

Claim 4

The apparatus of claim 1 further including second radiation curing means following said second dielectric depositing means.

Claim 5

The apparatus of claim 1 wherein said phosphor particulate mono-layer depositing means includes electrostatic depositing means having a phosphor source that has an electrically positive potential relative to an electrical potential associated with said carrier strip.

Claim 6

Apparatus as defined in claim 1 wherein said phosphor particulate mono-layer depositing means comprises electrostatic depositing means.

Claim 7

An electroluminescent panel, said panel comprising: a transparent insulating member; a first electrically conductive layer on said member, said first conductive layer being transparent; a first dielectric layer adjacent said first conductive layer, said first dielectric layer being transparent; a mono-layer of phosphor particulate adjacent said first dielectric layer, said phosphor particulate mono-layer having interstitial voids between adjacent particles comprising said phosphor particulate; a second dielectric layer adjacent said phosphor particulate mono-layer wherein said interstitial voids are substantially filled, said second dielectric layer overcoating said phosphor particles to embed them in a dielectric matrix, said second dielectric layer being transparent, and a second electrically conductive layer adjacent to said second dielectric layer; said second dielectric layer further forming a smooth surface on the side of said phosphor particulate mono-layer opposite said insulating member; said second electrically conductive layer further being a vapor deposited aluminum on said smooth surface of said second dielectric layer.

Claim 8

An electroluminescent panel, said panel comprising: a transparent insulating member; a first electrically conductive layer on said member, said first conductive layer being transparent; a first dielectric layer adjacent said first conductive layer, said first dielectric layer being transparent; a mono-layer of phosphor particulate adjacent said first dielectric layer, said phosphor particulate mono-layer having interstitial voids between adjacent particles comprising said phosphor particulate; a second dielectric layer adjacent said phosphor particulate mono-layer wherein said interstitial voids are substantially filled, said second dielectric layer overcoating said phosphor particles to embed them in a dielectric matrix, said second dielectric layer being transparent, and a second electrically conductive layer adjacent to said second dielectric layer; said second dielectric layer further forming a smooth surface on the side of said phosphor particulate mono-layer opposite said insulating member; said second electrically conductive layer further being a vapor deposited aluminum on said smooth surface of said second dielectric layer.

Claim 9

An electroluminescent panel, said panel comprising: a transparent insulating member; a first electrically conductive layer on said member, said first conductive layer being transparent; a first dielectric layer adjacent said first conductive layer, said first dielectric layer being transparent; a mono-layer of phosphor particulate adjacent said first dielectric layer, said phosphor particulate mono-layer having interstitial voids between adjacent particles comprising said phosphor particulate; a second dielectric layer adjacent said phosphor particulate mono-layer wherein said interstitial voids are substantially filled, said second dielectric layer overcoating said phosphor particles to embed them in a dielectric matrix, said second dielectric layer being transparent, and a second electrically conductive layer adjacent to said second dielectric layer; said second dielectric layer further forming a smooth surface on the side of said phosphor particulate mono-layer opposite said insulating member; said second electrically conductive layer further being disposed on said smooth surface of said second dielectric layer and reflective to light.

Claim 10

An electroluminescent panel, said panel comprising: a transparent insulating member; a first electrically conductive layer on said member, said first conductive layer being transparent; a first dielectric layer adjacent said first conductive layer, said first dielectric layer being transparent; a mono-layer of phosphor particulate adjacent said first dielectric layer, said phosphor particulate mono-layer having interstitial voids between adjacent particles comprising said phosphor particulate; a second dielectric layer adjacent said phosphor particulate mono-layer wherein said interstitial voids are substantially filled, said second dielectric layer overcoating said phosphor particles to embed them in a dielectric matrix, said second dielectric layer being transparent, and a second electrically conductive layer adjacent to said second dielectric layer; said second dielectric layer further forming a smooth surface on the side of said phosphor particulate mono-layer opposite said insulating member; said second electrically conductive layer further being disposed on said smooth surface of said second dielectric layer and reflective to light.

Claim 11

The panel of claim 7 wherein said first electrically conductive layer is indium-tin oxide.

Claim 12

The panel of claim 7 wherein said first dielectric layer is a high dielectric strength epoxy.

Claim 13

The panel of claim 7 wherein the thickness of said first dielectric layer is about 0.003-0.005 inch.

Claim 14

The panel of claim 7 wherein said phosphor particulate mono-layer is an electrostatically deposited layer embedded in said first dielectric layer.

Claim 15

The panel of claim 7 wherein said second dielectric layer is a high dielectric constant epoxy.

Claim 16

The panel of claim 7 wherein said second dielectric layer overcoats said phosphor particulate mono-layer to a thickness of at least about 0.003 inch.

Claim 17

The panel of claim 7 wherein said phosphor particulate mono-layer is electrostatically deposited adjacent said first dielectric layer.

Claim 18

Apparatus for making an electroluminescent panel, said apparatus comprising: first dielectric depositing means for depositing a first dielectric layer on a conductive layer of a carrier strip moving therepast; electrostatic depositing means for depositing a mono-layer of phosphor particulate on said first dielectric layer as said carrier strip moves therepast; second depositing means for alternatively depositing a second dielectric layer on said phosphor particulate mono-layer as the strip moves therepast from said electrostatic depositing means or depositing a mono-layer of phosphor particulate slurry on said conductive layer of said carrier strip as said carrier strip moves therepast while by-passing said first dielectric and said electrostatic depositing means, and means for moving said carrier strip past each of said first dielectric, said electrostatic and said second dielectric depositing means, respectively when said second depositing means deposits said second dielectric layer or for by-passing said first dielectric and said electrostatic depositing means respectively and moving said carrier strip directly past said second depositing means when it deposits said mono-layer of phosphor particulate slurry, said second depositing means including a reservoir for dielectric material comprising said second dielectric layer and another reservoir for said phosphor particulate slurry and valve means for alternatively supplying said dielectric material or said phosphor particulate slurry to said second depositing means, said first and second depositing means further including a knife-over roller depositor alternatively receiving said dielectric material or said phosphor particulate slurry.

Claim 19

Apparatus for making an electroluminescent panel, said apparatus comprising: first dielectric depositing means for depositing a first dielectric layer on a conductive layer of a carrier strip moving therepast; electrostatic depositing means for depositing a mono-layer of phosphor particulate on said first dielectric layer as said carrier strip moves therepast; second depositing means for alternatively depositing a second dielectric layer on said phosphor particulate mono-layer as the strip moves therepast from said electrostatic depositing means or depositing a mono-layer of phosphor particulate slurry on said conductive layer of said carrier strip as said carrier strip moves therepast while by-passing said first dielectric and said electrostatic depositing means, and means for moving said carrier strip past each of said first dielectric, said electrostatic and said second dielectric depositing means, respectively when said second depositing means deposits said second dielectric layer or for by-passing said first dielectric and said electrostatic depositing means respectively and moving said carrier strip directly past said second depositing means when it deposits said mono-layer of phosphor particulate slurry, said second depositing means including a reservoir for dielectric material comprising said second dielectric layer and another reservoir for said phosphor particulate slurry and valve means for alternatively supplying said dielectric material or said phosphor particulate slurry to said second depositing means, said first and second depositing means further including a knife-over roller depositor alternatively receiving said dielectric material or said phosphor particulate slurry.

Claim 20

The apparatus of claim 15 further including a movable first radiation curing means adjacent on e side of said carrier strip, and a second radiation curing means adjacent to the other side of said carrier strip and disposed downstream of said second depositing means.

Claim 21

Apparatus for making an electroluminescent panel, said apparatus comprising: first dielectric depositing means for depositing a first dielectric layer on a conductive layer of a carrier strip moving therepast; electrostatic depositing means for depositing a mono-layer of phosphor particulate on said first dielectric layer as said carrier strip moves therepast; second depositing means for alternatively depositing a second dielectric layer on said phosphor particulate mono-layer as the strip moves therepast from said electrostatic depositing means for depositing a mono-layer of phosphor particulate slurry on said conductive layer of said carrier strip as said carrier strip moves therepast while by-passing said first dielectric and said electrostatic depositing means, and means for moving said carrier strip past each of said first dielectric, said electrostatic and said second dielectric depositing means, respectively when said second depositing means deposits said second dielectric layer or for by-passing said first dielectric and said electrostatic depositing means, respectively and moving said carrier strip directly past said second depositing means when it deposits said mono-layer of phosphor particulate slurry, said first radiation curing means being movable from a position downstream of said first depositing means and upstream of said second depositing means when said second dielectric material is being deposited to a position downstream of said second depositing means when said phosphor particulate slurry is being deposited.

Claim 22

Apparatus for making an electroluminescent panel, said apparatus comprising: first dielectric depositing means for depositing a first dielectric layer on a conductive layer of a carrier strip moving therepast; electrostatic depositing means for depositing a mono-layer of phosphor particulate on said first dielectric layer as said carrier strip moves therepast; second depositing means for alternatively depositing a second dielectric layer on said phosphor particulate mono-layer as the strip moves therepast from said electrostatic depositing means for depositing a mono-layer of phosphor particulate slurry on said conductive layer of said carrier strip as said carrier strip moves therepast while by-passing said first dielectric and said electrostatic depositing means, and means for moving said carrier strip past each of said first dielectric, said electrostatic and said second dielectric depositing means, respectively when said second depositing means deposits said second dielectric layer or for by-passing said first dielectric and said electrostatic depositing means, respectively and moving said carrier strip directly past said second depositing means when it deposits said mono-layer of phosphor particulate slurry, said first radiation curing means being movable from a position downstream of said first depositing means and upstream of said second depositing means when said second dielectric material is being deposited to a position downstream of said second depositing means when said phosphor particulate slurry is being deposited.

Claim 23

Apparatus as defined in claim 10 wherein said phosphor particulate mono-layer depositing means comprises electrostatic depositing means.