Light Modulating Device Manufacturing Method for Uniform Liquid Crystal Distribution
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Solution Overview
Problem
Liquid crystal accumulation occurs in laminated glass used for light modulating devices, such as sunroofs and side windows, due to uneven distribution of liquid crystal, leading to reduced quality and appearance.
Innovation Solution
A manufacturing method for light modulating devices involves bonding a first laminated body with a glass sheet, an interlayer, and a light modulating cell to a second laminated body with a glass sheet and another interlayer, using a sealant to ensure even distribution of the liquid crystal layer, and optionally incorporating a gap layer or optically transparent adhesive film to prevent accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid crystal film is sandwiched between glass sheets via an interlayer to form laminated glass, then the light modulating function is achieved, but liquid crystal accumulation occurs due to uneven distribution, reducing quality and appearance
Solution Approach 1:
The glass sheet is divided into multiple segments (first glass sheet with first plurality of holes, second glass sheet with second plurality of holes) that are arranged in a grid pattern. The liquid crystal is supplied through these segmented holes, allowing for more uniform distribution across the entire area compared to a single large hole configuration.
Solution Approach 2:
Multiple liquid crystal supply holes are distributed locally across different regions of the glass sheets. Each hole serves as a local supply point, ensuring that liquid crystal is evenly distributed throughout the entire light modulating device rather than concentrating in one area.
2Strength
If pressure is applied to bond glass sheets together, then the laminated structure is formed, but liquid crystal accumulates in certain areas due to uneven pressure distribution
Solution Approach 1:
The bonding process is segmented into multiple stages with progressively increased pressure. The first pressure bonds the glass sheets initially, then a second higher pressure is applied to ensure complete bonding while allowing liquid crystal to distribute uniformly through the segmented hole structure.
Solution Approach 2:
Liquid crystal is supplied through the holes before the final bonding pressure is applied. This preliminary action ensures that the liquid crystal is in position and can be evenly distributed before the bonding process completes, preventing accumulation issues.
3Device complexity
If a single large hole is used for liquid crystal supply, then the structure is simple, but liquid crystal distribution becomes uneven causing accumulation
Solution Approach 1:
The single large liquid crystal supply hole is segmented into multiple smaller holes arranged in a grid pattern. This segmentation maintains relative structural simplicity while dramatically improving liquid crystal distribution uniformity across the entire device area.
Solution Approach 2:
The liquid crystal supply structure transitions from a single-point (0D) or line (1D) supply to a two-dimensional grid array of holes. This dimensional change allows liquid crystal to be supplied uniformly across the entire area, eliminating accumulation problems.
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 method effectively prevents liquid crystal accumulation, enhancing the quality and appearance of the light modulating device by ensuring even distribution of the liquid crystal layer, thereby maintaining optimal light control and reducing defects.
Implementation Method 1
The liquid crystal film changes the alignment of liquid crystal by changing the electric field applied between the transparent electrodes
Implementation Method 2
The liquid crystal film changes the alignment of liquid crystal by changing the electric field applied between the transparent electrodes
Implementation Method 3
bonding the first laminated body and the second laminated body, wherein the first glass sheet of the first laminated body and the second glass sheet of the second laminated body are bonded by a sealant
Data Source
AI summary
A manufacturing method for a light modulating device includes preparing a first laminated body including a first glass sheet, preparing a second laminated body in which a second glass sheet, a second interlayer, and a light modulating cell are laminated, and bonding the first laminated body and the second laminated body.