Pattern Structure for Large LCDs Using Flattening Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing large-size masters or stamps with uniform physical properties across the entire area are ineffective, particularly for metal wire grid polarizers in large-sized liquid crystal display panels, as they often result in defects and disconnections in the seam portions.
Innovation Solution
A pattern structure comprising a plurality of pattern structure units arranged on the same plane with a flattening layer connecting them, where each unit has microstructures on one surface and a flat second surface, allowing for a vertical step difference to be minimized, and using thermosetting or photocurable resins to ensure connection and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If current methods are used to manufacture large-size masters or stamps, then the manufacturing process is simple, but defects and disconnections occur in seam portions
Solution Approach 1:
The patent divides the large-size master or stamp into multiple smaller pattern structure units that are arranged in a matrix form. Each unit is manufactured separately with high precision, then combined to form the complete large-size structure. This segmentation allows each unit to be manufactured without defects while maintaining overall uniformity across the entire large-size master or stamp.
2Area of stationary object
If pattern structure units are arranged close to each other, then the seam portions are minimized, but vertical step differences cause microstructures to be at different heights
Solution Approach 1:
The patent introduces a flattening layer as an intermediary component between the pattern structure units. This flattening layer fills the vertical step differences caused by thickness variations of the pattern structure units, ensuring that all microstructures are positioned at the same height. The flattening layer acts as a mediator that maintains both the close arrangement for maximum coverage and the precision requirement for uniform microstructure height.
3Reliability
If a flattening layer is added to connect pattern structure units, then uniformity is improved, but device complexity increases
Solution Approach 1:
The patent uses a flattening layer made of resin material that is deposited uniformly across all pattern structure units. This homogeneous material fills the gaps and equalizes the heights, creating a uniform surface without requiring complex mechanical adjustment mechanisms. The resin-based approach provides a simple yet effective solution that improves uniformity while adding minimal structural 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 approach enables the manufacture of large-size metal wire grid polarizers with uniform physical properties without defects, effectively preventing disconnections and ensuring seamless images in large-sized LCDs by maintaining microstructures at the same height and using a connecting layer to bridge any thickness deviations.
Implementation Method 1
providing a flattening layer on the second surface of each of the plurality of pattern structure units, where the flattening layer connects the pattern structure units with each other
Implementation Method 2
the flattening layer may include a thermosetting resin or a photocurable resin
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A pattern structure includes a plurality of pattern structure units arranged substantially on a same plane, where each of the pattern structure units has a first surface and a second surface, which are opposite to each other, and a microstructure is defined on the first surface of each of the pattern structure units, and a flattening layer disposed on the second surface of each of the plurality of pattern structure units, where the flattening layer connects the pattern structure units with each other, and a vertical step difference exists between second surfaces of the pattern structure units.