Liquid Crystal Phase Shifter Spacers for Thick Cell Uniformity
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Solution Overview
Problem
Existing liquid crystal phase shifters face challenges in achieving uniform cell thickness due to limitations in spacer thickness, leading to deformation and poor performance, as current manufacturing methods struggle to produce spacers thicker than 100 µm, resulting in inadequate dielectric loss reduction and inconsistent phase modulation.
Innovation Solution
The use of epoxy or UV glue as spacers arranged on both substrates, with hot-press curing to form a housing of predetermined thickness, ensuring the liquid crystal layer thickness is maintained at 100-250 µm, and the spacers are evenly distributed to support the substrates, enhancing the phase shifter's performance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic ball spacers are used with current spraying methods, then manufacturing is simple, but spacer thickness cannot reach 100 µm and uniform distribution is poor
Solution Approach 1:
The patent changes the material parameter from plastic balls to photoresist material, and changes the thickness parameter from 30 µm maximum to 100 µm or above, while maintaining screen printing as the manufacturing method. This allows achieving both manufacturing simplicity and the required thickness precision.
Solution Approach 2:
The patent uses photoresist material combined with screen printing technology to create composite spacers that achieve both the required thickness (100 µm+) and uniform distribution, resolving the contradiction between ease of manufacture and manufacturing precision.
2Manufacturing precision
If photoresist is used with spin-coating process, then uniform coating is achieved, but spacer thickness is limited to 6-15 µm
Solution Approach 1:
The patent merges the advantages of photoresist material (uniform coating capability) with screen printing technology (thickness control), creating a hybrid approach that achieves both coating uniformity and the required spacer thickness of 100 µm or above.
Solution Approach 2:
The patent changes the process parameter from spin-coating to screen printing, which enables thickness control at 100 µm or above while maintaining the uniformity benefits of photoresist material.
3Length of stationary object
If sealant with high viscosity is used in screen printing, then spacer thickness can reach 100 µm or above, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameter from high viscosity sealant to photoresist material, which can be applied at lower viscosity and then cured to achieve the required thickness, thereby reducing manufacturing process complexity while maintaining spacer thickness of 100 µm or above.
4Loss of energy
If cell thickness is increased to 100-250 µm, then dielectric loss is reduced, but spacer thickness requirement becomes 100 µm or above which is difficult to manufacture
Solution Approach 1:
The patent uses photoresist material combined with screen printing to create spacers that are both manufacturable (using existing screen printing infrastructure) and thick enough (100 µm+) to support the 100-250 µm cell thickness required for low dielectric loss.
Solution Approach 2:
The patent changes the spacer material and process parameters to enable thickness of 100 µm or above, which directly supports the cell thickness increase needed to reduce dielectric loss, while maintaining ease of manufacture through screen printing.
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 allows for the production of liquid crystal phase shifters with consistent thickness and improved performance by ensuring the spacers and sealants are precisely arranged and cured, facilitating large-scale manufacturing of high-performance devices with reduced dielectric loss.
Implementation Method 1
the relationship between liquid crystal dielectric loss and liquid crystal cell thickness
Implementation Method 2
A phase shifter is a device which can adjust the phases of electromagnetic waves
Implementation Method 3
The use of epoxy or UV glue as spacers arranged on both substrates, with hot-press curing
Data Source
Figure 1~2
Figure 3
AI summary
The present disclosure provides a liquid crystal phase shifter, comprising a first substrate and a second substrate which are oppositely arranged, and a liquid crystal layer positioned between the first substrate and the second substrate, wherein a plurality of spacers are distributed in the liquid crystal layer, the spacers are in contact with the first substrate and the second substrate, and include a first spacer arranged on the first substrate and a second spacer arranged on the second substrate, and the first spacer and the second spacer are abutted. The present disclosure also provides a manufacturing method of the liquid crystal phase shifter. The first spacer and the second spacer are arranged on the first substrate and the second substrate respectively, so that the thickness of a support of the liquid crystal phase shifter being 100 µm or above is realized, and the performance of the liquid crystal phase shifter is ensured. Besides, the liquid crystal phase shifter is easy to manufacture, and the liquid crystal phase shifter with the thick cell can be manufactured on a large scale.