Liquid Crystal Antenna Stack With Single-Sided Electrode Patterning
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Solution Overview
Problem
The manufacturing of liquid crystal antennas is hindered by the high difficulty and low yield due to the complex process of patterning electrodes on both sides of substrates, leading to increased costs and reliability issues.
Innovation Solution
A liquid crystal antenna design featuring a first and second substrate forming a box-shaped structure with a conductive pattern layer on a single side of each, separated by a space, simplifying the manufacturing process and reducing costs by avoiding the need for dual-sided patterning, while maintaining performance through a second box-shaped structure with a conductive pattern layer on one side of the third substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are patterned on both sides of the substrate, then the antenna performance is improved, but the manufacturing difficulty increases and yield decreases
Solution Approach 1:
The patent divides the antenna structure into two separate box-shaped structures, each formed by two substrates with conductive pattern layers on single sides. This segmentation allows each unit to be manufactured independently with simpler single-sided patterning, avoiding the complexity of dual-sided patterning while maintaining the required antenna performance through the combined structure.
Solution Approach 2:
The patent transitions from a planar dual-sided electrode configuration to a three-dimensional stacked structure with box-shaped cavities. By utilizing the vertical dimension and creating separate enclosed spaces, the design achieves the necessary electromagnetic performance without requiring electrodes on both sides of a single substrate, thereby simplifying manufacturing.
2Reliability
If electrodes are patterned on both sides of the substrate, then the antenna performance is improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the antenna into multiple independent box-shaped units with single-sided conductive patterns, the patent reduces the overall manufacturing cost. Each unit can be produced using simpler and less expensive single-sided patterning processes, eliminating the need for costly dual-sided patterning equipment and processes while achieving the required performance through structural configuration.
3Ease of manufacture
If substrates are directly attached without spacing, then the manufacturing process is simplified, but protrusions and bulges occur reducing reliability
Solution Approach 1:
The patent incorporates spacing structures during the assembly process to pre-establish the correct distance between substrates before final attachment. This preliminary spacing action prevents the formation of protrusions and bulges that would occur with direct attachment, ensuring structural integrity and reliability while maintaining a streamlined manufacturing process.
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 configuration reduces manufacturing complexity, lowers costs, and enhances the reliability and yield of liquid crystal antennas by preventing protrusions and bulges, thereby improving the overall performance and quality of the antennas.
Implementation Method 1
Due to the anisotropy of the liquid crystals, the effective dielectric constant of the liquid crystals is adjustable to achieve the adjustment of wavelength
Data Source
AI summary
Provided are a liquid crystal antenna and a manufacturing method thereof. The liquid crystal antenna includes a first substrate, a second substrate and a third substrate that are stacked. The first substrate and the second substrate constitute a first box-shaped structure. A first space is disposed between the first substrate and the second substrate. The first space is filled with a liquid crystal layer. The second substrate and the third substrate constitute a second box-shaped structure. A second conductive pattern layer is disposed on a side of the second substrate. A third conductive pattern layer is disposed on a single side of the third substrate. A second space is disposed between the second substrate and the third substrate.