Patterned Phase Difference Film Air Exposure Control
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Solution Overview
Problem
The existing patterned phase difference films used in passive-type 3D display systems suffer from deteriorated photo-alignment properties when exposed to air during the formation process, leading to suboptimal performance.
Innovation Solution
A method involving the formation of a pattern alignment layer on a substrate, followed by heating and drying, and subsequent irradiation with polarized light, while minimizing exposure to air, to prevent deterioration, and the formation of a phase difference layer with a rod-like compound, ensuring high photo-alignment properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the photo-alignment film is exposed to air during the formation process, then the manufacturing process is simplified, but the photo-alignment property deteriorates
Solution Approach 1:
The patent applies the inert atmosphere principle by performing the photo-alignment process in an environment that prevents air exposure. Specifically, the heat-dried layer is irradiated with polarized light immediately after heating and drying without exposure to air, and the phase difference layer is formed continuously in the same environment. This inert environment protection prevents the photo-alignment film from deteriorating while maintaining manufacturing feasibility.
Solution Approach 2:
The patent implements continuity of useful action by performing the entire process—coating, heating and drying, polarized light irradiation, and phase difference layer formation—without interruption or exposure to air. The process flows continuously from one step to the next, ensuring the photo-alignment property is maintained throughout manufacturing.
2Adaptability or versatility
If the heat-dried layer is exposed to air before forming the phase difference layer, then the process flexibility increases, but the alignment regulation force deteriorates
Solution Approach 1:
The patent maintains the photo-alignment layer in an inert environment (protected from air) from the heating and drying step through the phase difference layer formation. This continuous protection in the same environment ensures the alignment regulation force is not deteriorated while still allowing process flexibility through continuous manufacturing.
3Productivity
If the photo-alignment layer is formed and then exposed to air, then the manufacturing time is reduced, but the adherence to substrate deteriorates
Solution Approach 1:
The patent ensures continuous manufacturing without interruption or air exposure between the photo-alignment layer formation and the phase difference layer formation. This continuous process maintains both high productivity and strong substrate adherence by preventing the photo-alignment layer from deteriorating through air exposure.
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 results in a patterned phase difference film with enhanced photo-alignment properties, suitable for high-quality 3D display applications by maintaining the alignment regulation force and adherence to the substrate.
Implementation Method 1
a pattern alignment layer which is formed on the substrate and in which an alignment pattern is formed... by irradiating the heat-dried layer with a polarized light pattern
Implementation Method 2
heating and drying the pattern alignment layer composition
Data Source
AI summary
A pattern phase difference film is manufactured by a process including a laminate body formation step of applying a pattern alignment layer composition on a substrate to form a laminate body, a heat-drying layer formation step of heat-drying the composition to form a heat-dried layer, a pattern alignment layer formation step of irradiating a polarization pattern onto the heat-dried layer to form a pattern alignment layer, and a phase difference layer formation step of forming a phase difference layer including a rod-shaped compound on the pattern alignment layer. During the steps between the heat-drying layer formation step and the phase difference layer formation step, the heat-dried layer and the pattern alignment layer are exposed to the air for four hours or less.