Optical Element With High Curvature Alignment Layer

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Solution Overview

Problem

Existing methods for manufacturing liquid crystal polarization elements are inefficient, requiring long times for optical axis alignment and limited to small areas, and cannot produce liquid crystal alignment patterns with short periods suitable for diffraction gratings.

Innovation Solution

An optical element with a support and an alignment layer featuring alternately arranged recess and protrusion portions with curvatures of 3.0 mm^-1 or higher, and a liquid crystal layer aligned along these structures, allowing for the formation of a diffraction grating with a short period through methods like nanoimprint or electron beam lithography.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photoalignment method using interference exposure is used, then liquid crystal alignment pattern can be formed, but manufacturing time becomes excessively long and only small area elements can be prepared

Engineering Contradiction:

Improveliquid crystal alignment patternVSAvoidmanufacturing speed and area

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the optical interference exposure method with a direct mechanical imprinting method. A stamper with a predetermined uneven structure is pressed onto a resist coating, transferring the pattern mechanically. This substitution of mechanical imprinting for optical exposure dramatically reduces manufacturing time and enables large-area production while maintaining precise alignment patterns.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent prepares a stamper with the desired uneven structure in advance. This pre-prepared stamper can be directly pressed onto the resist to transfer the pattern, eliminating the need for time-consuming interference exposure during the manufacturing process. The preliminary preparation of the stamper enables rapid production of alignment patterns.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If embossing method is used to form aligned microstructure, then various patterns including curves can be prepared, but liquid crystal alignment pattern with short period suitable for diffraction grating cannot be formed

Engineering Contradiction:

Improvepattern design flexibilityVSAvoidalignment pattern period

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent designs the stamper with specific local features including curved line shapes with controlled curvatures. By locally optimizing the stamper structure to include curves with curvatures of 3.0 mm⁻¹ or higher, the method achieves both the versatility of various pattern designs and the precision required for short-period alignment patterns suitable for diffraction gratings.

Inventive Principle:

Principle #3Local quality

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 approach enables high-productivity manufacturing of optical elements with liquid crystal alignment patterns suitable for diffraction gratings, offering improved efficiency and flexibility in pattern design compared to traditional methods.

Implementation Method 1

an alignment layer that is provided on one surface of the support and has an uneven structure in which a recess portion and a protrusion portion are alternately provided... and a liquid crystal layer having an alignment pattern in which an optical axis of a liquid crystal molecule is parallel to the surface of the support and is aligned along the recess portion and the protrusion portion in the alignment layer

Methodology Applied

Scientific EffectSurface alignment:

Data Source

PatentUS11402696B2Optical element and method of manufacturing optical element

Publication Date: 2022.08.02 FUJIFILM CORP

AI summary

An optical element includes: a support; an alignment layer that is provided on one surface of the support and has an uneven structure in which a recess portion and a protrusion portion are alternately provided, the recess portion extending in a line shape including a curve having a curvature of 3.0 mm−1 or higher, and the protrusion portion extending in a line shape including a curve having a curvature of 3.0 mm−1 or higher; and a liquid crystal layer having an alignment pattern in which an optical axis of a liquid crystal molecule is parallel to the surface of the support and is aligned along the recess portion and the protrusion portion in the alignment layer.