Flexible LCD Polymer Barrier Formation via UV Photopolymerization
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Solution Overview
Problem
Conventional flexible liquid crystal display panel manufacturing methods are complex and costly due to the use of expensive fine masks for creating polymer barriers, which also suffer from precision issues and increased production costs.
Innovation Solution
A method involving light-shielding patterns on a rigid base, where a liquid crystal layer with polymerizable monomers is aligned between substrates, and UV light is used to form an organic polymer barrier between these patterns, eliminating the need for fine masks and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine mask is used to form the polymer barrier, then the barrier can be created, but the manufacturing precision deteriorates due to slit diffraction and the device complexity increases
Solution Approach 1:
The patent extracts and removes the fine mask component from the manufacturing process entirely. Instead of using a mask with openings to define the barrier pattern, the invention uses direct UV irradiation through a transparent substrate to polymerize monomers in the liquid crystal layer, forming the barrier without any mask material. This eliminates mask-related diffraction issues and simplifies the device structure.
Solution Approach 2:
The patent introduces a transparent substrate as an intermediary element that enables precise UV light transmission to form the polymer barrier. This substrate acts as a mediator between the UV light source and the liquid crystal layer, allowing controlled polymerization without requiring a physical mask. The transparent substrate provides structural support while permitting optical access for barrier formation.
2Manufacturing precision
If a fine mask is used to form the polymer barrier, then the barrier can be created, but the production cost increases due to mask expense and complex processing
Solution Approach 1:
The patent replaces expensive, complex fine masks with a simple, inexpensive transparent substrate that can be easily manufactured and disposed of or reused. The transparent substrate serves its purpose during the barrier formation process and can be removed or retained without adding significant cost. This substitution dramatically reduces material costs and simplifies manufacturing operations.
Solution Approach 2:
By removing the fine mask from the process, the patent eliminates the associated costs of mask fabrication, alignment, and handling. The extraction of this costly component and replacement with a simple transparent substrate directly reduces production expenses while maintaining or improving barrier quality through more precise UV-controlled polymerization.
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 approach enhances the fineness of the polymer barrier, reduces production costs, and simplifies the manufacturing process by avoiding slit diffraction and mask-related complexities, ensuring higher quality and cost-effectiveness.
Implementation Method 1
using an ultraviolet (UV) light to irradiate the liquid crystal cell at a side of the rigid base away from second substrate in order to form an organic polymer barrier
Data Source
AI summary
A manufacturing method for a flexible liquid crystal display panel is provided. The method includes steps of: providing multiple light-shielding patterns disposed at a side of the rigid base and arranged as a matrix, providing a second substrate disposed at a side of the multiple light-shielding patterns away from the rigid base or disposed at a side of rigid base away from the multiple light-shielding patterns; aligning a side of the second substrate away from the rigid base with the first substrate, disposing a liquid crystal layer between the first substrate and the second substrate to obtain a liquid crystal cell, wherein the liquid crystal layer includes liquid crystal molecules and polymerizable monomer, and using an ultraviolet light to irradiate the liquid crystal cell at a side of the rigid base away from second substrate to form an organic polymer barrier corresponding to a gap between the light-shielding patterns.