Liquid Crystal Panel Columnar Spacer Formation via Photopolymerization

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Solution Overview

Problem

The conventional manufacture process of liquid crystal panels is complex and inefficient, requiring multiple steps for columnar spacer formation after the overcoat and alignment film processes, which can lead to defects like rubbing mura due to height differences.

Innovation Solution

A method where photopolymerizable monomers in the liquid crystal layer are polymerized to form columnar spacers after the substrates are assembled, using light irradiation with masks to create spacers of varying heights, simplifying the process and eliminating the need for multi-step spacer formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional multi-step process (photoresist coating, exposing, developing, shaping) is used to form columnar spacer, then spacer formation is achieved, but manufacturing complexity increases and productivity decreases

Engineering Contradiction:

Improvecolumnar spacer formation precisionVSAvoidmanufacture process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the chemical state of the liquid crystal material by incorporating photopolymerizable monomers that can be activated by light exposure. This parameter change allows the liquid crystal to transform from a fluid state to a polymerized solid state, forming columnar spacers directly without mechanical processing steps

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical multi-step photoresist processing system with a photochemical polymerization system. Instead of using photoresist coating, exposing, developing, and shaping operations, the invention uses light-induced polymerization of photopolymerizable monomers within the liquid crystal material to directly form the desired spacer structures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional multi-step process is used for columnar spacer manufacture, then spacer structure is formed, but production time increases and efficiency decreases

Engineering Contradiction:

Improvecolumnar spacer structure accuracyVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges multiple separate manufacturing steps into a single integrated process. The photopolymerizable monomers are mixed into the liquid crystal material in advance, and a single light exposure step simultaneously achieves both the formation of columnar spacers and the alignment of liquid crystal molecules, eliminating the need for separate photoresist processing steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary action by incorporating photopolymerizable monomers into the liquid crystal material before the liquid crystal cell assembly. This pre-preparation allows the material to be ready for direct polymerization upon light exposure, eliminating the need for on-site photoresist coating and processing

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If columnar spacer is formed before substrate assembly, then spacer position is controlled, but process complexity and risk of defects increase

Engineering Contradiction:

Improvecolumnar spacer position accuracyVSAvoiddisplay quality consistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent performs preliminary action by preparing the photopolymerizable monomers within the liquid crystal material before cell assembly, but the actual polymerization to form spacers occurs after assembly. This timing allows the spacers to form in their final positions within the cell, eliminating risks associated with handling and alignment during pre-assembly spacer formation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent enables the liquid crystal material to self-organize into columnar spacer structures through photoinduced polymerization. The photopolymerizable monomers automatically form spacers at appropriate locations based on the liquid crystal flow and alignment during cell assembly, without requiring external positioning or alignment steps

Inventive Principle:

Principle #25Self-service

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 simplifies the manufacturing process, reduces production costs, and improves display quality by avoiding defects associated with traditional spacer formation methods, while using cost-effective and widely available photopolymerizable monomers.

Implementation Method 1

exposing the liquid crystal layer to allow the photopolymerizable monomers to be polymerized at a position of exposing to form a columnar spacer

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11326101B2Liquid crystal panel and manufacture method thereof, liquid crystal display device

Publication Date: 2022.05.10 BOE TECHNOLOGY GROUP CO LTD

AI summary

A liquid crystal panel and a manufacture method thereof, a liquid crystal display device are disclosed. The manufacture method of a liquid crystal panel includes: providing a first substrate, a second substrate and a liquid crystal layer between the first substrate and the second substrate, wherein the liquid crystal layer includes a liquid crystal material and photopolymerizable monomers; and exposing the liquid crystal layer to allow the photopolymerizable monomers to be polymerized at a position of exposing to form a columnar spacer.