Coated Polarizer Formation on Uneven Black Ink Surfaces
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Solution Overview
Problem
The manufacturing process of display devices faces challenges in forming a coated-type polarizer directly on cover glass due to the thickness of black ink used for decorative printing, which conceals the internal structure and improves design, making it difficult to align the polymerizable liquid crystal layer and alignment film effectively.
Innovation Solution
A display device configuration that includes a polarization layer with a polymerizable liquid crystal layer and an alignment film, where the alignment film contacts the polymerizable liquid crystal layer only in the display region to form a polarization portion and not in the frame region, allowing for the formation of a black frame portion, facilitating easier manufacturing of the coated-type polarizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If black ink is applied for decorative printing to conceal internal structure, then aesthetic appearance is improved, but the surface becomes uneven and coated-type polarizer formation becomes difficult
Solution Approach 1:
The invention divides the polarizer formation process into two independent parts: (1) forming the alignment film directly on the cover glass (including over the black ink frame), and (2) forming the polymerizable liquid crystal layer on top of the alignment film. This segmentation allows the polarizer to be formed without requiring a flat surface, as the alignment film adapts to the uneven black ink surface while the liquid crystal layer forms uniformly above it.
Solution Approach 2:
The alignment film serves as an intermediary layer between the uneven black ink surface and the polymerizable liquid crystal layer. This intermediate layer bridges the gap between the aesthetically important but surface-creating black ink and the functionally important liquid crystal layer, allowing both to coexist without interfering with each other's formation.
2Adaptability or versatility
If black ink printing is performed before polarizer formation, then design flexibility is improved, but manufacturing complexity increases due to surface unevenness
Solution Approach 1:
The manufacturing process is segmented into independent stages: first applying the black ink for decorative purposes, then forming the alignment film that conforms to the existing surface, and finally forming the liquid crystal layer. This segmentation eliminates the need to sequence operations in a specific order, allowing design flexibility while maintaining manufacturing simplicity.
Solution Approach 2:
The invention changes the critical parameter from surface flatness to film conformability. By selecting materials and processes where the alignment film can conform to uneven surfaces and the liquid crystal layer can form uniformly above such surfaces, the manufacturing complexity is reduced despite the presence of decorative black ink.
3Productivity
If polymerizable liquid crystal layer is formed directly on cover glass, then manufacturing steps are reduced, but alignment quality deteriorates without alignment film contact
Solution Approach 1:
The alignment film acts as an essential intermediary between the cover glass and the polymerizable liquid crystal layer. It provides the necessary alignment function through direct contact with the liquid crystal molecules, ensuring proper orientation and polarization quality while still allowing the liquid crystal layer to be formed in a single coating step over the entire surface.
Solution Approach 2:
The alignment film provides localized alignment quality where needed (in the display region where liquid crystal contact occurs) while allowing the frame region to maintain its decorative black ink appearance. This local quality approach ensures manufacturing precision in critical areas without compromising overall manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration simplifies the formation of the coated-type polarizer, eliminates the need for separate black ink printing, and reduces the complexity of forming the polarizer on uneven surfaces, thereby making the manufacturing process more efficient.
Implementation Method 1
an alignment film coming in contact with a portion of the polymerizable liquid crystal layer configured to align the polymerizable liquid crystal contained in the polymerizable liquid crystal layer with which the alignment film is in contact
Implementation Method 2
a polymerizable liquid crystal layer containing a polymerizable liquid crystal into which a dichroic pigment is mixed
Data Source
AI summary
In order to make a step of forming an coated-type polarizer easier, provided is a display device including, from a lower layer, a TFT layer, a light-emitting layer, a sealing layer, and a polarization layer in this order, in which the polarization layer includes a polymerizable liquid crystal layer containing a polymerizable liquid crystal into which a dichroic pigment is mixed and an alignment film coming in contact with a portion of the polymerizable liquid crystal layer to align the polymerizable liquid crystal contained in the polymerizable liquid crystal layer with which the alignment film is in contact, and in a display region, a region in which the polymerizable liquid crystal layer and the alignment film of the polarization layer come into contact with each other is a polarization portion, andin a frame region surrounding the display region, a region in which the polymerizable liquid crystal layer and the alignment film of the polarization layer do not come in contact with each other is a black frame portion.