One Drop Filling Liquid Crystal Panel Fabrication
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Solution Overview
Problem
Existing liquid crystal panel fabrication methods face challenges in ensuring even mixing of composite materials, leading to inconsistent quality and efficiency, particularly with blue phase liquid crystals which require proper dissolution of components to maintain desirable characteristics.
Innovation Solution
A fabrication method involving heating the first substrate and liquid crystal material to a temperature above the blue phase point, followed by assembly with a second substrate under controlled temperatures, and using a sealant that is solidified through photo-curing or thermal-curing processes, ensuring the liquid crystal material is evenly distributed and maintaining viscosity to prevent rapid spraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional liquid crystal panel fabrication methods are used without heating, then the fabrication process is simpler, but the components in the liquid crystal material are not evenly mixed, leading to inconsistent quality
Solution Approach 1:
The patent applies parameter changes by heating the liquid crystal material and first substrate to a first fabrication temperature (below 70°C) during the one drop filling process. This temperature parameter change enables the components in the liquid crystal material to be evenly mixed while maintaining the blue phase characteristics, thereby improving manufacturing precision without excessive process complexity
Solution Approach 2:
The patent applies preliminary action by pre-heating both the liquid crystal material and the first substrate to the first fabrication temperature before performing the one drop filling process. This preliminary heating ensures that when the liquid crystal material is dropped, the components are immediately and evenly mixed, preventing quality inconsistency from the outset
2Manufacturing precision
If high temperature heating is used to mix components, then even mixing is achieved, but the blue phase characteristics of the liquid crystal material are lost
Solution Approach 1:
The patent precisely controls the temperature parameter by specifying that the first fabrication temperature must be below 70°C and not exceed the blue phase point of the liquid crystal material. This parameter optimization achieves even mixing of components while preserving the essential blue phase characteristics, resolving the contradiction between mixing quality and material properties
Solution Approach 2:
The patent applies dynamics by maintaining the liquid crystal material and substrate at a dynamic thermal state during the one drop filling process. The temperature is controlled to be above the blue phase point but below 70°C, creating an optimal window where the material remains in the desired blue phase while achieving sufficient molecular mobility for even mixing
3Ease of operation
If the one drop filling process is performed at room temperature, then the process is easier to control, but the liquid crystal material viscosity is too high, causing rapid spraying and the drop mura effect
Solution Approach 1:
The patent changes the temperature parameter from room temperature to a controlled first fabrication temperature (above blue phase point but below 70°C). This parameter adjustment optimizes the viscosity of the liquid crystal material, preventing both excessive thickness and rapid spraying, thereby eliminating the drop mura effect while maintaining good process control
Solution Approach 2:
The patent applies preliminary action by pre-heating the liquid crystal material to the optimal temperature range before the one drop filling process. This preliminary temperature adjustment ensures the material has the right viscosity for controlled dropping and even distribution, preventing the drop mura effect before it occurs
4Device complexity
If the liquid crystal material is dropped without heating the substrate, then the assembly process is simpler, but the components do not mix evenly, resulting in quality inconsistency
Solution Approach 1:
The patent applies preliminary action by pre-heating the first substrate to the first fabrication temperature before performing the one drop filling process. This preliminary heating of the substrate ensures that when the liquid crystal material is dropped, immediate and even mixing occurs upon contact, achieving high manufacturing precision without significantly complicating the assembly process
Solution Approach 2:
The patent changes the substrate temperature parameter from ambient to a controlled first fabrication temperature (below 70°C and above blue phase point). This parameter change creates an optimal thermal environment on the substrate surface that promotes even mixing of liquid crystal components while maintaining process simplicity
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 method enhances the fabrication efficiency and quality of liquid crystal panels by ensuring even mixing of components, maintaining blue phase characteristics, and preventing the drop mura effect, resulting in improved panel performance and consistency.
Implementation Method 1
A first substrate and a liquid crystal material are heated to a first fabrication temperature and a one drop filling process is simultaneously performed
Implementation Method 2
the method of solidifying the sealant includes a photo-curing process, a thermal-curing process, or a combination thereof
Implementation Method 3
the method of solidifying the sealant includes a photo-curing process, a thermal-curing process, or a combination thereof
Data Source
AI summary
A fabrication method of a liquid crystal panel is provided. A first substrate and a liquid crystal material are heated to a first fabrication temperature and a one drop filling (ODF) process is performed to drop the heated liquid crystal material on the first substrate, wherein the first fabrication temperature is lower than 70° C. The first substrate is assembled to a second substrate through a sealant under a second fabrication temperature so that the liquid crystal material is sandwiched between the first substrate and the second substrate and located inside a region surrounded by the sealant, wherein the second fabrication temperature is 50° C. to 70° C. Subsequently, the sealant is solidified.