Folded Monolithic Optical Cell for Reduced Manufacturing Complexity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing multiple layered liquid crystal optical devices require multiple connections and complex stacking processes, leading to increased cost, complexity, and reduced yield, as they rely on multiple stacked cells with separate connections and adhesives.
Innovation Solution
A single monolithic process is used to create a longer optical cell that is folded back on itself, allowing for multiple layered optical cells with a single connection and flexible design, using a single substrate layer for multiple cells and minimizing the need for intercellular adhesives, which can be bent to form complex stacks and various optics designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple liquid crystal cells are stacked on top of each other to increase optical power, then the optical power is improved, but the device complexity and manufacturing cost increase due to multiple connections and adhesives required
Solution Approach 1:
The patent merges multiple separate liquid crystal cells into a single monolithic optical cell with multiple internal layers. Instead of stacking independent cells that require separate connections and adhesives, the invention creates one integrated cell structure where multiple optical layers coexist within a single cell boundary, eliminating the need for inter-cell connections and adhesive layers.
Solution Approach 2:
The single monolithic optical cell performs multiple optical functions that would traditionally require separate cells. By integrating multiple functional layers within one cell structure, the device achieves multi-functionality without requiring multiple independent cell units, thereby reducing overall device complexity while maintaining enhanced optical power.
2Ease of operation
If multiple connections are used to connect each optical cell in the stack, then each cell can be individually addressed, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent segments the internal structure of the single optical cell into multiple functional layers, each capable of being independently controlled. This segmentation allows individual addressing of different optical functions within the cell while maintaining a unified external structure that requires fewer connections than multiple separate cells would demand.
Solution Approach 2:
Multiple cell connections are merged into a single cell structure. The invention combines what would traditionally be separate connection interfaces into one unified connection system, reducing the total number of connections required while preserving the ability to individually address and control different optical layers within the cell.
3Stability of the object's composition
If adhesive is used between each optical cell in the stack, then the cells are held together, but the manufacturing yield is reduced due to potential glue intermixing and defects
Solution Approach 1:
The patent eliminates the need for adhesive layers between multiple cells by merging them into a single monolithic structure. The internal layers are held together through integrated structural design rather than external adhesives, removing the manufacturing defects and yield issues associated with glue application and intermixing while maintaining stable layer alignment.
Data Source
AI summary
We disclose an optical device comprising an optical stack. The optical stack comprises a first substrate layer, a second substrate layer, and an optical medium located between the first and second substrate layers. The optical stack is bent such that a second portion of the optical stack extends behind a first portion of the optical stack.