Liquid Crystal Sheet With Segmented Alignment Regions
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Solution Overview
Problem
Existing methods for manufacturing liquid crystal optical elements, particularly those used in near-eye displays, face challenges in achieving uniformity and quality when using batch processes, especially due to complex optical designs.
Innovation Solution
A sheet comprising a liquid crystal layer with multiple liquid crystal alignment pattern regions, arranged in orthogonal directions with non-aligned regions in between, and surrounded by outer peripheral regions. This configuration allows for efficient cutting into specified regions to form liquid crystal optical elements with improved uniformity and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch process is used to manufacture liquid crystal optical elements with complex optical designs, then manufacturing flexibility and quality control are improved, but manufacturing productivity and efficiency deteriorate
Solution Approach 1:
The invention divides the liquid crystal layer into multiple independent liquid crystal alignment pattern regions, each capable of being processed and cut separately. This segmentation allows batch processing of multiple elements simultaneously while maintaining the quality control benefits of individual processing, thus resolving the contradiction between manufacturing precision and productivity.
2Productivity
If roll-to-roll process is used for mass production, then manufacturing productivity is improved, but the ability to handle complex optical designs deteriorates
Solution Approach 1:
By segmenting the liquid crystal layer into multiple independent alignment pattern regions, the invention enables roll-to-roll processing of complex optical designs. Each region can be independently designed with complex optical patterns while the overall structure allows continuous batch production, thus achieving both high productivity and complex design capability.
Solution Approach 2:
The invention applies local quality by allowing different regions of the liquid crystal layer to have different alignment patterns optimized for specific optical functions. This enables complex optical designs in localized areas while maintaining overall manufacturing efficiency through batch processing.
3Productivity
If liquid crystal alignment pattern regions are arranged closely to maximize area utilization, then manufacturing efficiency is improved, but uniformity of quality deteriorates due to interference between regions
Solution Approach 1:
The invention introduces non-aligned regions as intermediary zones between liquid crystal alignment pattern regions. These non-aligned regions act as buffers that prevent optical and physical interference between adjacent pattern regions, allowing closer arrangement for higher manufacturing efficiency while maintaining uniform quality across all regions.
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 proposed solution enhances the uniformity and quality of liquid crystal optical elements manufactured by batch processes, while also improving manufacturing efficiency and stability, even for complex optical designs.
Implementation Method 1
a liquid crystal layer having a plurality of liquid crystal alignment pattern regions with a liquid crystal alignment pattern in which an orientation of optical axes derived from a liquid crystal compound changes while continuously rotating
Implementation Method 2
a liquid crystal layer exhibiting optical anisotropy
Data Source
AI summary
An object of the present invention is to provide a sheet capable of increasing uniformity of quality of a liquid crystal optical element manufactured by a batch process. Another object of the present invention is to provide a manufacturing method of a liquid crystal optical element. The sheet of the present invention is a sheet including a liquid crystal layer containing a liquid crystal compound, in which the liquid crystal layer has a plurality of liquid crystal alignment pattern regions having a liquid crystal alignment pattern in which an orientation of optical axes derived from the liquid crystal compound changes while continuously rotating in at least one in-plane direction, the plurality of liquid crystal alignment pattern regions are arranged to be spaced apart from each other in two directions orthogonal to each other in a plane of the liquid crystal layer, with a non-aligned region interposed between liquid crystal alignment pattern regions, two or more of the liquid crystal alignment pattern regions are arranged in each of the two directions in the liquid crystal layer, the non-aligned region is a region having no liquid crystal alignment pattern and no slow axis, an outer periphery of the liquid crystal alignment pattern region is surrounded by an outer peripheral region, the outer peripheral region is a region having no liquid crystal alignment pattern and having a slow axis, and a specified region including the liquid crystal alignment pattern region is capable of being cut out as a liquid crystal optical element.