Reflective film display device that is electromechanically actuated, method of manufacturing the same, and method of manufacturing cantilever for display for reflective film display device

A reflective film display device including first and second display units to which a driving signal is supplied, the second display unit being stacked on the first display unit, and each of the first and second display units comprising:

• an alignment structure configured to align the second display unit with the first display unit;
• a stationary electrode provided on the alignment structure;
• movable cantilevers, each configured to elastically deformed and having a movable display piece at its free end, a first gap being formed between the free end of the movable cantilever and the stationary electrode, the movable cantilevers being fixed to the alignment structure;
• stationary cantilevers, each mounted on the movable cantilever in conformity with the movable cantilever and having a stationary display piece provided at a free end, a second gap being provided between the movable and stationary display pieces;
• and
• a wiring configured to supply a driving signal to the stationary electrode and the movable cantilever, the wiring being aligned with the stationary electrode and the movable cantilever by the alignment structure, and the movable cantilever being elastically deformed to allow the movable display piece of the second display unit to be displaced to a position behind the stationary display piece of the first display unit.

A method of manufacturing a reflective film display device, comprising:

• preparing first and second display units, each including:
• preparing a wiring board having conducting lines configured to be applied with voltage signals;
• preparing a alignment structure having a stationary electrode and including a receiving section and first and second position aligning members;
• fitting the wiring board in the receiving section to fix the wiring board on the alignment member, one of the conducting lines being electrically connected to the stationary structure;
• arranging movable cantilevers in a predetermined array on a mount base, each of the movable cantilevers configured to elastically deformed and having a free end portion which is folded to provide a movable display piece;
• positioning the first alignment member on the mount base to align the conducting lines with the corresponding movable cantilevers, respectively, fixing the movable cantilevers on the alignment structure to provide gaps between the movable cantilevers and the stationary electrode, respectively, and removing the alignment structure from the mount base;
• and
• mounting stationary cantilevers on the movable cantilevers, respectively, each of the stationary cantilevers having a free end which is folded to provide a stationary display piece, and fixing the stationary cantilevers on the movable cantilevers to provide gaps between the movable and stationary display pieces;
• and
• positioning the second alignment member of the second display unit on the first display unit to align the movable cantilevers of the second display unit to the corresponding stationary cantilevers of the first display unit, the stationary and movable display pieces being arranged in a grid and the movable cantilever being bent upon application of the voltage signal to displace the movable display piece of the second display unit to a position behind the stationary display piece of the first display unit.

A method of manufacturing a cantilever for display for a reflective film display device, comprising:

• preparing a rectangular resin film coated with a conductive layer;
• cutting the rectangular resin film to form a plurality of strip-like movable cantilevers extending substantially in parallel to each other and having a free end portion each;
• preparing a pair of blocks, each having a holding surface and a slidable surface, and arranging the pair of blocks such that the holding surfaces face each other and the slidable surfaces aligned in a reference plane;
• holding the movable cantilevers substantially in parallel to each other between the holding surfaces of the blocks to project the free end portions of the movable cantilever from the reference plane;
• preparing a press member having a flat smooth surface and sliding the press member on the slidable surfaces of the blocks to fold the free end portions of the movable cantilever and to allow the pressurizing member to press the free end portion against one of the slidable surfaces, and heating the movable cantilevers with the free end portion thus pressed;
• and
• gradually cooling the movable cantilever and releasing the movable cantilever from the blocks.