Liquid Crystal Phase Shifter Support Structure for Cell Gap Uniformity
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Solution Overview
Problem
Existing liquid crystal phase shifters have large cell gaps, leading to uneven thickness and poor uniformity of the liquid crystal layer, which affects the stability of microwave signal transmission due to process errors and inadequate support structures.
Innovation Solution
A liquid crystal phase shifting unit with a support structure between substrates to steadily support the liquid crystal filling region, improving cell gap uniformity and avoiding interference with microwave signal transmission by positioning the support structure to not overlap with the microstrip line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a liquid crystal groove is provided on the second rigid substrate to support the liquid crystal layer, then the cell gap can be maintained, but process errors lead to uneven thickness and poor uniformity of the liquid crystal layer
Solution Approach 1:
The support function is segmented from the substrate and implemented through discrete support structures (ribs) distributed in the liquid crystal filling region. These support structures are formed separately from the substrates and microstrip line, allowing independent optimization of each component's function and reducing the impact of process errors on overall uniformity.
Solution Approach 2:
Support structures act as intermediary elements between the first and second substrates, providing mechanical support to maintain cell gap uniformity without requiring the substrates themselves to provide support through grooves or other complex features. This intermediary support structure resolves the contradiction by decoupling the support function from the substrate fabrication process.
2Reliability
If the support structure is positioned to support the liquid crystal filling region, then cell gap uniformity is improved, but it may overlap with the microstrip line and affect microwave signal transmission
Solution Approach 1:
The support structures are strategically positioned in specific regions of the liquid crystal filling region where they are needed for support, while deliberately avoiding areas where the microstrip line is located. This localized placement ensures that support function is provided where required without interfering with microwave signal transmission paths.
Solution Approach 2:
The problem of overlap between support structures and microstrip line is resolved by considering the three-dimensional spatial arrangement. The support structures extend between the substrates in the vertical dimension, while the microstrip line is confined to the horizontal plane on the substrate surface. By ensuring the orthographic projection of the support structure does not overlap the microstrip line in the horizontal plane, the patent eliminates interference while maintaining vertical support function.
3Manufacturing precision
If a liquid crystal groove is provided on the substrate, then the liquid crystal layer can be contained, but the groove thickness varies due to process errors affecting cell gap uniformity
Solution Approach 1:
The support function is extracted from the substrate structure and implemented through separate support structures formed in the liquid crystal filling region. This extraction eliminates the need for complex groove structures on the substrates, simplifying the manufacturing process while maintaining cell gap uniformity through the dedicated support structures.
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 uniformity of the liquid crystal layer thickness and improves the stability of microwave signal transmission by eliminating the need for a liquid crystal groove on the substrate and preventing the support structure from affecting the signal, thus reducing manufacturing complexity and costs.
Implementation Method 1
A phase shifter is a device capable of adjusting a phase of a wave, and is widely used in various fields... The current widely used phase shifter is the liquid crystal phase shifter
Data Source
AI summary
Provided are a liquid crystal phase shifting unit, a method for manufacturing the same, a liquid crystal phase shifter, and an antenna, which relate to the technical field of phase shifting. A liquid crystal filling region (6) is supported steadily by a support structure (4), which increases the transmission stability of a microwave signal. A space between a first substrate (1) and a second substrate (2) of the liquid crystal phase shifting unit includes the liquid crystal filling region (6). A microstrip line (3) is provided on a surface of the first substrate (1) facing towards the second substrate (2). An orthographic projection of the microstrip line (3) on the first substrate (1) is located in the liquid crystal filling region (6). The support structure (4) is provided between the first substrate (1) and the second substrate (3) and in the liquid crystal filling region (6). The orthographic projection of the support structure (4) on the first substrate (1) does not overlap the microstrip line (3), which is used for shifting a phase of a microwave signal.