Non-Rectangular Polarizing Plate Asymmetric Geometry Reworking
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Solution Overview
Problem
Conventional polarizing plates, especially when thin or large, are prone to tearing or breaking during the reworking process due to their rectangular shape, which complicates the recycling of liquid crystal cells and affects the handling of thin or large LCDs.
Innovation Solution
A non-rectangular polarizing plate with interior angles between 80° to 100° and an in-plane absorption axis, where a hypothetical rectangle drawn parallel or perpendicular to the absorption axis has sides that make acute angles of 1° to 5° with the non-rectangular shape, reducing the force applied during reworking and preventing tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the polarizing plate thickness is reduced to make LCDs thinner, then the overall display thickness is reduced, but the polarizing plate becomes more vulnerable to tearing or breaking during reworking
Solution Approach 1:
The patent applies asymmetry by changing the polarizing plate shape from a symmetric rectangle to an asymmetric non-rectangular shape with at least one acute angle between 1° to 5°. This asymmetric geometry redistributes stress during the peeling process, preventing concentration at corner points and thereby reducing tearing and breaking even when the plate is thin (120 μm or less)
2Area of stationary object
If the polarizing plate size is increased for large displays, then the display area is increased, but the plate becomes more prone to tearing or breaking during reworking
Solution Approach 1:
For large displays (longest side 700 mm or more), the patent employs asymmetric non-rectangular shapes that eliminate corner stress concentration points. The acute angles (1° to 5°) in the asymmetric design prevent force concentration during diagonal peeling, maintaining high reworking success rates even for large-area plates
3Ease of manufacture
If a rectangular polarizing plate is used with absorption axis at 0°, 90° or 45° to the side, then the manufacturing is simplified, but the plate tears or breaks during peeling due to force concentration at corners
Solution Approach 1:
The patent resolves the contradiction by adopting asymmetric non-rectangular shapes instead of symmetric rectangles. This eliminates corner stress concentration while maintaining manufacturing feasibility through standardized cutting processes. The asymmetric geometry works effectively with conventional absorption axis orientations (0°, 90°, or 45° to the side)
Solution Approach 2:
The patent applies parameter changes by modifying the geometric parameters of the polarizing plate from rectangular dimensions to non-rectangular dimensions with specific acute angles (1° to 5°). This parameter modification changes the stress distribution characteristics during peeling, preventing tearing and breaking while maintaining ease of manufacture
Data Source
AI summary
A polarizing plate of the present invention comprises: main four sides which form a quadrangle or a substantially quadrangular shape, wherein the quadrangle or the substantially quadrangular shape is a non-rectangular shape having four interior angles each of which is in the range of 80° to 100°, provided that at least two of the four interior angles are not 90°, the non-rectangular polarizing plate has an in-plane absorption axis, a largest rectangle having four sides in directions parallel and perpendicular to the absorption axis of the polarizing plate can be drawn as a hypothetical rectangle in the plane of the non-rectangular polarizing plate, the hypothetical rectangle has a side which is closest to the non-rectangular shape and makes angles in the range of 0° to 5° with the non-rectangular shape, and at least one of the angles is an acute angle in the range of 1° to 5°. The polarizing plate can smoothly undergo reworking even when it has a reduced thickness.