Light-Modulating Cell Sealing via Alignment Film Permeation
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Solution Overview
Problem
The existing light-modulating cells face challenges in securing strong adhesion of sealing materials to alignment films, especially when using resin as a base material, due to weak adhesive forces and gas generation, which affects long-term reliability and makes it difficult to form sealing materials using methods like roll-to-roll where electrodes are not exposed.
Innovation Solution
A stacked structure with a permeation region on the alignment film where sealing material components, including thermosetting epoxy resin, penetrate up to 30 nanometers or more, ensuring strong adhesion and allowing the sealing material to be firmly attached to the alignment film, even when resin is used as a base material, and incorporating a photocurable component for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sealing material is applied only on the electrode portion, then strong adhesion is achieved through the electrode-sealing material bond, but it becomes impossible to form sealing material in areas where the electrode is not exposed
Solution Approach 1:
The alignment film serves as an intermediary substrate that enables the sealing material to adhere to areas where the electrode is not exposed. The sealing material forms a bank shape on the alignment film, allowing it to extend beyond the electrode boundaries and provide complete sealing coverage around the liquid crystal layer.
Solution Approach 2:
The sealing material is configured to extend in multiple dimensions: it covers the electrode portion where strong adhesion occurs, and simultaneously extends onto the alignment film in areas where the electrode is not exposed, achieving both strong bonding and complete sealing coverage.
2Adaptability or versatility
If the sealing material is applied on the alignment film, then complete sealing coverage is achieved, but the adhesion between the sealing material and alignment film is weak
Solution Approach 1:
The sealing material's adhesion function is segmented into two zones: one zone on the electrode portion where strong adhesion provides anchoring, and another zone on the alignment film where the sealing material forms a bank shape to provide coverage and sealing functionality.
3Ease of manufacture
If resin is used as the base material supporting the electrode, then manufacturing flexibility is improved, but gas generation weakens the adhesion between sealing material and alignment film
Solution Approach 1:
The sealing material is applied and configured to form a bank shape on the alignment film before the resin base material is heated and gas is generated. This preliminary positioning ensures that the sealing material maintains its adhesion and sealing function even after gas generation occurs during subsequent heating processes.
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 ensures robust and reliable adhesion of the sealing material to the alignment film, maintaining strong adhesion even with gas generation, and enables effective sealing in areas where electrodes are not exposed, improving the durability and manufacturing feasibility of light-modulating cells.
Implementation Method 1
the first alignment film has a permeation region where at least a part of components constituting the sealing material permeate
Implementation Method 2
A stacked structure with a permeation region on the alignment film where sealing material components, including thermosetting epoxy resin, penetrate up to 30 nanometers or more, ensuring strong adhesion
Implementation Method 3
incorporating a photocurable component for enhanced bonding
Data Source
AI summary
A stacked body includes a first resin film, a first electrode portion, a first alignment film, and a sealing material which are stacked, wherein the first alignment film has a permeation region where at least a part of components constituting the sealing material permeate.