Optical Component Manufacturing Using Polarized UV Light
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Solution Overview
Problem
Conventional manufacturing processes for optical components with retardation films are costly due to the use of expensive alignment films and complex deposition processes, which increase the overall cost and complexity of producing optical components like liquid crystal displays and organic EL displays.
Innovation Solution
A method involving irradiation of a transparent base material with linearly polarized ultraviolet light to impart alignment properties directly to the base material, allowing a polymerizable liquid crystal compound to be aligned without the need for an additional alignment film, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an alignment film is used to align the polymerizable liquid crystal compound, then the liquid crystal compound can be properly aligned, but the manufacturing cost increases due to the expensive alignment film and complex deposition process
Solution Approach 1:
The invention extracts and eliminates the alignment film from the conventional manufacturing process. Instead of using a separate alignment film layer, the base material itself is modified through UV irradiation to provide alignment properties directly, thereby removing the need for the alignment film and simplifying the manufacturing process while maintaining alignment precision
Solution Approach 2:
The invention merges the functions of the base material and the alignment film into a single integrated system. The base material is subjected to UV irradiation to create alignment properties, combining the structural support function and the alignment function into one component, thereby reducing the number of layers and manufacturing steps
2Manufacturing precision
If an alignment film is deposited on the base material, then the polymerizable liquid crystal compound can be aligned, but the number of manufacturing steps and process complexity increase
Solution Approach 1:
The invention extracts the alignment function from the alignment film and transfers it to the base material through UV irradiation. This eliminates the need for depositing a separate alignment film layer, thereby reducing the number of manufacturing steps and process complexity while maintaining the necessary alignment precision
Solution Approach 2:
The invention performs preliminary action by subjecting the base material to UV irradiation before applying the polymerizable liquid crystal compound. This pre-treatment creates the alignment properties on the base material surface in advance, eliminating the need for subsequent alignment film deposition and reducing overall process complexity
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 enables the production of optical components with retardation layers more easily and cost-effectively by eliminating the need for expensive alignment films and complex deposition processes, while maintaining alignment properties across a wide wavelength band.
Implementation Method 1
irradiating a base material that is substantially transparent to light having a wavelength for which the optical component is used with linearly polarized ultraviolet light having a wavelength of 200 nm or less
Implementation Method 2
stacking a polymerizable liquid crystal compound on the base material after the irradiation with the linearly polarized ultraviolet light, and forming a retardation layer by allowing the polymerizable liquid crystal compound to be aligned
Data Source
AI summary
A method of manufacturing an optical component includes the steps of irradiating a base material that is substantially transparent to light having a wavelength for which the optical component is used with linearly polarized ultraviolet light having a wavelength of 200 nm or less, stacking a polymerizable liquid crystal compound on the base material after the irradiation with the linearly polarized ultraviolet light, and forming a retardation layer by allowing the polymerizable liquid crystal compound to be aligned in accordance with the state of the base material.