Large-Area Electro-Optic Display via Segmented Tiled Units
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Solution Overview
Problem
Existing large-area light modulators and displays face challenges in manufacturing large polymer structures that concentrate charged particles without compromising optical transparency, especially when trying to cover large areas such as office building windows or wide format signs.
Innovation Solution
A large-area electro-optic device is constructed using a side-by-side tiled arrangement of electro-optic units, each comprising light-transmissive substrates with electrically-conductive vias and layers, and an electro-optic medium layer. This configuration allows for reliable electrical connections to each unit without compromising transparency, enabling the use of conventional equipment for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large polymer structures are used to concentrate charged particles, then particle concentration is improved, but optical transparency deteriorates
Solution Approach 1:
The device is divided into multiple small electro-optic units (e.g., 10x10 array of 1 cm² units) that are tiled together to form a large-area device. Each unit contains its own polymer structure for particle concentration, allowing the system to achieve both high particle concentration in each unit and large overall area while maintaining optical transparency through the use of transparent substrates and conductive layers.
2Ease of manufacture
If conventional equipment is used for manufacturing, then manufacturing complexity is reduced, but large-area production capability deteriorates
Solution Approach 1:
The manufacturing process is segmented into producing small electro-optic units using conventional equipment, then tiling and assembling these units into large-area configurations. This allows conventional manufacturing equipment to be used for each unit while achieving large overall device areas through modular assembly.
Solution Approach 2:
Multiple small electro-optic units are merged together in a tiled arrangement to create a large-area device. The units are combined using transparent substrates and conductive layers that maintain both the electrical functionality of individual units and the optical transparency of the overall device.
3Reliability
If electrical connections are added to each unit, then device functionality is improved, but optical transparency deteriorates
Solution Approach 1:
The electrical connections are implemented with light-transmissive conductive layers and vias that are optimized for both electrical conductivity and optical transparency. The conductive vias extend through the substrates to provide reliable electrical connections while minimizing their visual impact and maintaining overall device transparency.
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
The solution allows for the production of large-area light modulators and displays that maintain optical transparency and can be manufactured using conventional equipment, addressing the limitations of existing technologies in covering large areas effectively.
Implementation Method 1
an electrophoretic medium layer between and in contact with the first and second light-transmissive electrically-conductive layers
Implementation Method 2
Large-area electro-optic device... electro-optic units... electro-optic medium layer
Data Source
AI summary
A large-area switchable electro-optic light modulator or display and method of manufacture are disclosed. The large-area light modulator comprises an array of individual light modulator units sandwiched between two larger light-transmissive substrates coated on their inner surfaces with light-transmissive electrode layers with electrical connections to each unit that do not compromise the transparency of the light modulator in an open state. The large-area display comprises an array of individual display units. A large-area light-transmissive substrate coated on its inner surface with a light-transmissive electrode layer is superposed on the individual display units with electrical connections to each unit that do not compromise the transparency of the display. The light modulator and the display can be readily manufactured using conventional equipment.