Liquid Crystal Alignment Layer Reuse via Peelable Interface
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Solution Overview
Problem
The existing methods for manufacturing liquid crystal layers face challenges in achieving sufficient alignment of liquid crystal compounds, particularly when the alignment film is reused, leading to inadequate alignment and reduced productivity, especially when forming smaller period patterns.
Innovation Solution
A method involving the repeated use of an alignment film, where a first liquid crystal composition is aligned and polymerized to form a liquid crystal alignment layer, which is then peeled off and reused, allowing a second liquid crystal composition to be aligned and polymerized on its surface to form a liquid crystal layer, without the need for a peelable layer, utilizing a photo-alignment film with an azobenzene compound and polyfunctional polymerizable compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a peelable layer is provided between the liquid crystal alignment layer and the liquid crystal layer to enable peeling, then the alignment film can be reused, but the alignment of the liquid crystal layer becomes insufficient
Solution Approach 1:
The invention extracts and eliminates the peelable layer from the structure, allowing the liquid crystal alignment layer to be in direct contact with the liquid crystal layer. This removal of the intermediate peelable layer resolves the alignment insufficiency problem while maintaining alignment film reusability through the liquid crystal alignment layer's designed peeling capability from the alignment film.
Solution Approach 2:
The liquid crystal alignment layer is designed to serve multiple functions: it provides alignment properties for the liquid crystal layer, enables peeling from the alignment film for reuse, and eliminates the need for a separate peelable layer. This multi-functionality resolves the contradiction by integrating the peeling function into the alignment layer itself.
2Productivity
If the liquid crystal layer is formed on the surface of the liquid crystal alignment layer opposite to the alignment film, then productivity is improved through alignment film reuse, but the aligning properties of the liquid crystal compound become low
Solution Approach 1:
The invention applies local quality by providing different surface characteristics on the liquid crystal alignment layer: one surface maintains alignment properties for contact with the alignment film, while the opposite surface is specifically designed with enhanced aligning properties for contact with the liquid crystal layer. This ensures sufficient alignment even when the liquid crystal layer is formed on the opposite surface.
Solution Approach 2:
The invention changes the surface parameters of the liquid crystal alignment layer by controlling the polymerization conditions and composition to create a surface with appropriate aligning properties. By adjusting the polymerization degree and surface chemistry, the alignment capability is maintained or enhanced on the surface opposite to the alignment film.
3Ease of operation
If a peelable layer is present between the liquid crystal alignment layer and the liquid crystal layer, then peeling can be performed, but the alignment of the formed liquid crystal layer is not sufficient, especially in smaller period patterns
Solution Approach 1:
The invention extracts and removes the peelable layer from the structure, allowing direct contact between the liquid crystal alignment layer and the liquid crystal layer. The peeling function is instead achieved through the controlled interface between the liquid crystal alignment layer and the alignment film, eliminating the intermediate layer that degraded alignment quality.
Solution Approach 2:
The invention creates an asymmetric structure where the liquid crystal alignment layer has different interaction characteristics with the alignment film versus the liquid crystal layer. The interface with the alignment film is designed for easy peeling, while the interface with the liquid crystal layer provides strong alignment, resolving the contradiction through asymmetric design.
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 high alignment quality of the liquid crystal layer and improves productivity by maintaining alignment film properties over multiple uses, enhancing the alignment of liquid crystal compounds in the layer without the interference of a peelable layer, thus achieving better alignment and efficiency.
Implementation Method 1
utilizing a photo-alignment film with an azobenzene compound
Implementation Method 2
the liquid crystal composition is aligned to a predetermined alignment state by applying the liquid crystal composition for forming the liquid crystal layer to the alignment film formed on a support and aligning the applied liquid crystal composition
Implementation Method 3
a first liquid crystal composition including a polymerizable liquid crystal compound on the alignment film and aligning the first liquid crystal composition; a liquid crystal alignment layer forming step of polymerizing the aligned first liquid crystal composition to form a liquid crystal alignment layer
Data Source
AI summary
An object is to provide a method of manufacturing a liquid crystal layer in which an alignment film is repeatedly used and a liquid crystal compound in a liquid crystal layer can be sufficiently aligned. The method of manufacturing a liquid crystal layer includes: an alignment film forming step of forming an alignment film on a support; a liquid crystal alignment film alignment step of laminating a first liquid crystal composition including a polymerizable liquid crystal compound on the alignment film and aligning the first liquid crystal composition; a liquid crystal alignment layer forming step of polymerizing the aligned first liquid crystal composition to form a liquid crystal alignment layer; a peeling step of laminating and immobilizing a surface of the liquid crystal alignment layer opposite to the alignment film on an adherend and peeling the liquid crystal alignment layer from the alignment film at an interface between the liquid crystal alignment layer and the alignment film; a liquid crystal layer alignment step of laminating a second liquid crystal composition including a polymerizable liquid crystal compound on a surface of the liquid crystal alignment layer from which the alignment film is peeled off and aligning the second liquid crystal composition; a liquid crystal layer forming step of polymerizing the aligned second liquid crystal composition to form a liquid crystal layer; and a liquid crystal layer separation step of separating the formed liquid crystal layer from the liquid crystal alignment layer, in which the liquid crystal layer alignment step to the liquid crystal layer separation step are repeated to repeatedly prepare the liquid crystal layer.