Laser-Patterned Light Control Sheet for Curved Electrode Layouts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing light control sheets with multiple light control sections require complex patterning processes for transparent electrode layers, increasing production steps and costs, and making it difficult to design changes and form curved surfaces.

Innovation Solution

A light control sheet with a laser-irradiated insulating portion in the first transparent electrode layer, reducing the need for photolithography and etching, allowing for easier design modifications and curved surface production by forming the insulating section directly in the transparent conductive layer during multilayer laminate processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photolithography and etching processes are used to pattern transparent electrode layers, then precise insulating portions can be formed, but production steps and costs increase

Engineering Contradiction:

Improveprecision of insulating portion formationVSAvoidcomplexity of production process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/chemical photolithography and etching processes with laser irradiation to form insulating portions directly in the transparent electrode layer. The laser beam selectively irradiates specific regions to create insulating portions without requiring complex patterning processes, thereby reducing production steps while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state or properties of the transparent electrode layer through laser irradiation parameters (energy density, irradiation time, wavelength) to create insulating portions. By controlling laser parameters, the transparent conductive oxide layer is selectively transformed into an insulating state in targeted areas, eliminating the need for traditional patterning.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional patterning processes are used, then insulating portions can be formed, but design changes become difficult

Engineering Contradiction:

Improveeffectiveness of light transmittance controlVSAvoidease of design modification

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces flexibility and adaptability to the manufacturing process by using laser irradiation, which can be easily reprogrammed and adjusted. Unlike fixed photolithography masks, laser parameters and irradiation patterns can be dynamically changed to accommodate design modifications, making the production process adaptable to different configurations while maintaining reliable light transmittance control.

Inventive Principle:

Principle #15Dynamics

3Productivity

If conventional production methods are used, then light control sheets can be manufactured, but curved surface production is difficult

Engineering Contradiction:

Improveproduction efficiencyVSAvoidease of curved surface production

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces rigid mechanical patterning processes with flexible laser irradiation that can accommodate curved surfaces. The laser beam can be focused and directed onto non-planar surfaces, enabling the formation of insulating portions on curved transparent electrode layers without requiring complex mechanical tooling or flat substrate handling.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method reduces production steps and costs by simplifying the patterning process, enabling easier design changes and facilitating the production of light control sheets with curved surfaces while maintaining effective light transmittance control.

Implementation Method 1

conducting laser irradiation to the multilayer laminate such that a laser beam penetrates one of the first and second transparent support layers located closer to a laser source than the first transparent conductive layer, and that an insulating portion is formed in the first transparent conductive layer

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11442320B2Light control sheet and method of producing light control sheet

Publication Date: 2022.09.13 TOPPAN HOLDINGS INC

AI summary

A method of producing a light control sheet includes forming a multilayer laminate in which a light control layer comprising a liquid crystal composition is sandwiched between a first transparent conductive layer formed on a first transparent support layer and a second transparent conductive layer formed on a second transparent support layer, and conducting laser irradiation to the multilayer laminate such that a laser beam penetrates one of the first and second transparent support layers located closer to a laser source than the first transparent conductive layer, and that an insulating portion is formed in the first transparent conductive layer.