Variable Transmittance Optical Stack Without Spacers or Alignment Films
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Solution Overview
Problem
Conventional variable transmittance optical stacks face issues with complex manufacturing processes, increased costs, damage to alignment films, and difficulty in maintaining uniform optical color due to the use of spacers, and they require separate substrates and alignment films for conductive layers, leading to thickness and transmittance limitations.
Innovation Solution
A variable transmittance optical stack with a liquid crystal layer containing a polymer network and a conductive polymer, where the conductive layer serves as both an electrode and alignment film, eliminating the need for separate substrates and alignment films, and maintaining a robust cell gap without spacers, thereby simplifying the manufacturing process and reducing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spacer is used to maintain cell gap in liquid crystal layer, then cell gap can be maintained, but manufacturing process becomes complex and alignment film is damaged
Solution Approach 1:
The invention extracts and removes the spacer component from the liquid crystal display structure. Instead of using physical spacers to maintain cell gap, the patent employs a polymer network formed within the liquid crystal layer itself to maintain the cell gap, thereby eliminating the complex spacer manufacturing process and avoiding alignment film damage.
Solution Approach 2:
The invention merges the cell gap maintenance function with the liquid crystal layer by forming a polymer network directly within it. This integration eliminates the need for separate spacer components and simplifies the manufacturing process while maintaining precise cell gap control.
2Manufacturing precision
If a ball spacer is used to maintain cell gap, then cell gap can be maintained, but uniform optical color in plane cannot be maintained and current short circuit occurs
Solution Approach 1:
The invention removes ball spacers from the liquid crystal layer structure. By forming a polymer network directly in the liquid crystal layer, the patent eliminates the issues of optical non-uniformity and electrical short circuits associated with ball spacers, while maintaining reliable cell gap control.
3Ease of manufacture
If separate substrate and alignment film are used for conductive layer, then conductive layer can be formed, but thickness increases and transmittance decreases
Solution Approach 1:
The invention merges the conductive layer formation process with the existing substrate or alignment film structure. By integrating the conductive function into existing components rather than adding separate layers, the patent reduces overall thickness while maintaining ease of manufacture through established processes.
Solution Approach 2:
The invention makes existing components multi-functional by enabling them to serve both as structural elements and as conductive layers. This eliminates the need for additional dedicated conductive substrate layers, thereby reducing overall device thickness while maintaining manufacturing simplicity.
4Ease of manufacture
If separate substrate and alignment film are used for conductive layer, then conductive layer can be formed, but transmittance in light transmissive mode decreases
Solution Approach 1:
The invention combines the conductive layer formation with existing transparent components, eliminating additional light-blocking layers. By integrating conductivity into existing transparent structures rather than adding separate conductive substrates, the patent maintains high light transmittance while preserving manufacturing ease.
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 configuration improves driving stability, allows for uniform light transmittance adjustment, reduces manufacturing complexity and costs, and enhances transmittance in light transmissive mode by eliminating the need for additional substrates and alignment films.
Implementation Method 1
a liquid crystal layer containing a polymer network and a liquid crystal compound, and the liquid crystal compound is arranged with uniform initial alignment
Implementation Method 2
a variable transmittance optical stack capable of changing the transmittance of light when voltage is applied
Data Source
AI summary
A variable transmittance optical stack a manufacturing method therefor, a smart window including the same, and windows for an automobile or a building using the same are proposed.