Liquid Crystal Element Dark Line Reduction

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Solution Overview

Problem

Existing lighting apparatuses using liquid crystal elements suffer from poor light distribution patterns due to gaps between pixel electrodes, which result in conspicuous dark lines and increased manufacturing costs when attempting to minimize these gaps or thin wiring, leading to resistance and disconnection issues.

Innovation Solution

A liquid crystal element configuration with columnar spacers and strategically designed pixel and inter-pixel electrodes, along with a common electrode, to maintain a prescribed gap and prevent dark lines, while ensuring sufficient voltage application and minimizing bright spots, using a vertically aligned liquid crystal layer between polarizers and a projection lens for improved light distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the gap between pixel electrodes is narrowed to reduce dark lines, then the appearance of light distribution pattern is improved, but manufacturing cost increases and short circuit risk increases

Engineering Contradiction:
Improveappearance of light distribution patternVSAvoidshort circuit risk
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

A light-shielding film is introduced as an intermediary layer between adjacent pixel electrodes. This film extends from the surface of the first substrate toward the second substrate, creating a physical barrier that prevents short circuits while allowing the gap between pixel electrodes to be minimized for improved appearance. The light-shielding film acts as a mediator that resolves the contradiction by providing electrical isolation without requiring larger gaps.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Illumination intensity

If the wiring part between pixel electrodes is thinned to reduce dark lines, then the appearance of light distribution pattern is improved, but resistance increases and disconnection probability increases

Engineering Contradiction:
Improveappearance of light distribution patternVSAvoiddisconnection probability
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

The light-shielding film is strategically positioned only in specific locations where it is needed for isolation, rather than uniformly across the entire structure. The film extends from the first substrate surface toward the second substrate in regions between pixel electrodes, providing localized quality enhancement. This allows the wiring to maintain sufficient thickness for reliability while the light-shielding film prevents dark line formation in the gaps.

Inventive Principle:
Principle #3Local quality

3Ease of manufacture

If the gap between pixel electrodes is increased to facilitate wiring extension, then manufacturing is easier, but dark lines become more conspicuous

Engineering Contradiction:
Improvewiring extensionVSAvoiddark line visibility
Core Design Contradiction:
Ease of manufactureVSIllumination intensity

Solution Approach 1:

The light-shielding film serves as an intermediary element that decouples the relationship between gap size and dark line visibility. By introducing this film, the gap can be maintained at a larger size for ease of wiring extension and manufacturing, while the film itself blocks light leakage that would create dark lines. This resolves the contradiction by allowing both larger gaps and reduced dark line visibility through the mediating film.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 solution enhances the appearance of light distribution patterns by reducing dark lines and bright spots, maintaining manufacturing efficiency and ensuring effective voltage application, thereby improving the overall performance and aesthetics of the lighting apparatus.

Implementation Method 1

a liquid crystal layer (18) disposed between the first substrate (10) and the second substrate (20)

Methodology Applied
Scientific EffectLiquid crystal electro-optic effect: Electro-Optic Effects

Implementation Method 2

columnar spacers (30, 31) made of, for example, a resin film are dispersedly arranged between the upper substrate (11) and the lower substrate (12)

Methodology Applied
Scientific EffectMechanical support:

Implementation Method 3

a vertically aligned liquid crystal layer between polarizers

Methodology Applied
Scientific EffectPolarization: Polarisation

Data Source

PatentEP3647863B1Liquid crystal element, lighting apparatus
Publication Date: 2023.12.27 STANLEY ELECTRIC CO LTD
  • EP3647863B1 patent drawingFigure 1
  • EP3647863B1 patent drawingFigure 2A~2C
  • EP3647863B1 patent drawingFigure 3

AI summary

To improve the appearance of a light distribution pattern, a liquid crystal element includes: a first substrate (11); a second substrate (12); a liquid crystal layer (18); and columnar bodies (30); where the first substrate has a counter electrode (13) provided on its one surface side; where the second substrate is configured to include wiring parts (15, 16) provided on its one surface side, an insulating layer (17) provided on the upper side of the wiring parts, and pixel electrodes (14) provided on the upper side of the insulating layer; where the pixel electrodes are arranged along a first direction; where each wiring (16a, 16b, 16c) part is connected to one of the pixel electrodes, arranged on the lower layer side of the pixel electrodes, and has a connection region (516c) that passes through a gap between the pixel electrodes adjacent to each other in the first direction; and where the columnar bodies is provided at a position overlapping the connection region.