Optical Element Conductive Column Spacer Integration
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Solution Overview
Problem
The manufacturing of optical elements, such as light adjustment panels, is complicated by the need for precise spacer formation to maintain a cell gap between substrates, which is time-consuming and requires specialized equipment.
Innovation Solution
The optical element design incorporates a conductive column and spacers made of the same material, extending along the outer periphery of the liquid crystal layer, with the conductive column electrically connecting electrodes and spacers positioned on the inner and outer sides of the sealing member, simplifying the manufacturing process by using the same equipment for both components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate materials and processes are used for spacers and sealing members, then functional requirements are met, but manufacturing complexity increases
Solution Approach 1:
The patent combines the spacer and sealing member into a single integrated component formed from the same material. The spacer portion and sealing member portion are both formed from resin material containing conductive particles, eliminating the need for separate materials and assembly steps while maintaining both the cell gap maintenance function and the sealing function.
Solution Approach 2:
The resin material containing conductive particles serves multiple functions simultaneously: it maintains the cell gap through the spacer portion, provides sealing through the sealing member portion, and ensures electrical conductivity throughout the structure. This multi-functional material approach reduces manufacturing complexity while meeting all functional requirements.
2Manufacturing precision
If specialized equipment is used for spacer formation, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The spacer and sealing member are formed in a single molding process using the same resin material with conductive particles. This integration eliminates the need for specialized spacer formation equipment and separate assembly steps, allowing standard molding equipment to produce both components with consistent precision while significantly improving manufacturing efficiency.
Solution Approach 2:
The patent changes the material parameters by using resin containing conductive particles, which allows the spacer to be formed with sufficient electrical conductivity using conventional molding processes. This material parameter change enables the use of standard equipment rather than specialized equipment, maintaining precision while improving productivity.
3Reliability
If multiple materials are used for different components, then functional performance is optimized, but manufacturing costs increase
Solution Approach 1:
The patent uses a single resin material containing conductive particles for both the spacer and sealing member portions. This material integration eliminates the need to source, store, and process multiple different materials, reducing material costs and manufacturing complexity while maintaining the electrical conductivity and functional performance required for both components.
Data Source
AI summary
According to an aspect, an optical element includes: a first substrate including a first electrode; a second substrate stacked on the first substrate and including a second electrode; a liquid crystal layer provided between the first substrate and the second substrate; a sealing member extending along an outer periphery of the liquid crystal layer; a first spacer provided on an inner side of the sealing member; and a conductive column provided on an outer side of the sealing member and electrically connecting the first electrode and the second electrode. The conductive column and the first spacer include the same material.