Patterned Retarder Film with Interleaved Grating Stripe Structures
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Solution Overview
Problem
Existing methods for manufacturing patterned retarder films for liquid crystal display screens are limited in providing effective three-dimensional stereo imaging, as they lack a novel and efficient embossing method for creating micro-structured retarder films with distinct phase retardation regions.
Innovation Solution
A patterned retarder film is manufactured using an embossing method involving a first substrate with a phase retardation layer composed of interleaved grating-like stripe structures of liquid crystal materials and curable resin, where the first and second retardation regions provide different phase retardations by 180°, achieved through a process of substrate lamination and alignment layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture patterned retarder films, then manufacturing simplicity is maintained, but manufacturing precision and stereo imaging quality deteriorate
Solution Approach 1:
The manufacturing process is divided into distinct stages: forming the patterned configuration with curable resin, curing it, forming an alignment layer, filling liquid crystal material, and final lamination. Each stage produces a specific intermediate structure that builds toward the final patterned retarder film, enabling precise control over the grating-like stripe patterns and phase retardation regions.
Solution Approach 2:
The curable resin is embossed with a predetermined pattern to form the patterned configuration before curing. This preliminary structuring establishes the grating-like stripe patterns and defines the first and second regions that will provide different phase retardations, ensuring precision is built into the structure from the outset rather than added later.
2Manufacturing precision
If phase retardation regions are created without embossing, then manufacturing simplicity is maintained, but manufacturing precision and phase retardation control deteriorate
Solution Approach 1:
The patterned configuration creates distinct first regions and second regions with different local properties. The curable resin is embossed to form grating-like stripe patterns where certain regions (first regions) will contain liquid crystal material providing a specific phase retardation, while other regions (second regions) provide a different phase retardation by 180°. This local differentiation enables precise control over phase retardation in different areas of the film.
Solution Approach 2:
The embossing process changes the physical parameters of the curable resin by creating a three-dimensional patterned configuration with specific depths and widths. After curing, this structure allows selective filling of liquid crystal material in the first regions, creating controlled phase retardation differences. The embossing depth and pattern dimensions directly control the final phase retardation characteristics.
3Manufacturing precision
If alignment is not precisely controlled, then manufacturing simplicity is maintained, but manufacturing precision and stereo imaging quality deteriorate
Solution Approach 1:
An alignment layer is introduced as an intermediary component between the patterned configuration and the liquid crystal material. This alignment layer is formed on the cured patterned configuration and provides a controlled surface that guides the orientation of liquid crystal molecules during filling. The alignment layer mediates the interaction between the rigid patterned structure and the fluid liquid crystal material, ensuring precise alignment without complex external alignment mechanisms.
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
The method enables the production of patterned retarder films that provide enhanced three-dimensional imaging capabilities by ensuring precise alignment and phase retardation differences, improving the stereo imaging experience for viewers.
Implementation Method 1
The curable resin is embossed with a predetermined pattern to form a patterned configuration comprising a plurality of first regions and a plurality of second regions
Implementation Method 2
The patterned configuration is then cured
Implementation Method 3
An alignment layer is provided to the first regions of the phase retardation layer in order to align with the liquid crystal in said regions
Implementation Method 4
The first retardation regions provide a first phase retardation and the second retardation regions provide a second phase retardation and the first phase retardation and the second phase retardation are different by 180°
Implementation Method 5
A second substrate is provided to be pressed-laminated on the phase retardation layer
Implementation Method 6
The laminated patterned retarder film is conducted a heating treatment to align the liquid crystal materials of the first regions with the alignment layer
Data Source
AI summary
A patterned retarder film and a method for manufacturing the same are provided. A patterned retarder film with a micro-structure comprises a first substrate, a phase retardation layer on the first substrate comprising a plurality of first retardation regions of liquid crystal materials and a plurality of second retardation regions of curable resin, wherein the structures of the first retardation regions and the second retardation regions are grating-like stripe structures and parallelly interleaved with each other and the first retardation regions provide a first phase retardation and the second retardation regions provide a second phase retardation; and a second substrate laminated on the phase retardation layer; wherein the first phase retardation and the second phase retardation are different by 180°. The method for manufacturing the patterned retarder film is also disclosed