Recessed Insulating Layer for Uniform Alignment in Electro-Optical Devices

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Solution Overview

Problem

In liquid crystal display devices, the alignment layer thickness is often non-uniform between the effective display region and the peripheral region due to material flow, leading to uneven display brightness.

Innovation Solution

A recessed portion is formed in the peripheral region to prevent the alignment layer material from flowing into the effective display region, ensuring uniform coating and preventing brightness inconsistencies by using a spin coating method and burning the coated material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the alignment layer is coated on the peripheral region with higher stacked components, then the alignment layer material flows into the effective display region, but the alignment layer thickness becomes non-uniform and alignment failure occurs

Engineering Contradiction:

Improvealignment layer coatingVSAvoidalignment layer thickness uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The peripheral region is segmented into multiple sub-regions with different heights by forming recessed portions. This segmentation prevents the alignment layer material from flowing continuously into the effective display region, thereby maintaining uniform thickness across the entire alignment layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the peripheral region are given different local qualities by forming recessed portions at specific locations. The recessed portions create localized variations in height that control material flow, allowing the alignment layer to maintain uniform thickness while accommodating the multi-gap structure.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the stacked components height is increased in the peripheral region for multi-gap structure, then the liquid crystal layer thickness can be controlled, but the alignment layer material flows excessively into the effective display region

Engineering Contradiction:

Improveliquid crystal layer thickness controlVSAvoidalignment layer thickness uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The recessed portions are formed in advance during the manufacturing process, before the alignment layer coating step. This preliminary action pre-establishes barriers that will prevent excessive material flow during subsequent coating operations, ensuring uniform alignment layer thickness.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The recessed portions act as intermediary structures between the peripheral region and the effective display region. These recessed portions mediate the interaction between the alignment layer material and the different height regions, controlling material flow while maintaining the multi-gap structure's functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 uniform alignment layer formation in both the effective display and peripheral regions, maintaining consistent display brightness and preventing alignment failures.

Implementation Method 1

The alignment layer is formed by coating solution made of a material, such as polyimide, on a substrate by means of a spin coating method

Methodology Applied

Scientific EffectSpin coating: Spin Coating

Implementation Method 2

then burning the coated material

Methodology Applied

Scientific EffectBurning: Combustion

Data Source

PatentUS8009253B2Electro-optical device having insulating layer with varying thickness in the reflection and transmission displays

Publication Date: 2011.08.30 MAGNOLIA WHITE CORP

AI summary

An electro-optical device includes: a sealant provided between a pair of substrates in a frame shape; an electro-optical material layer formed by sealing an electro-optical material within a region surrounded by the sealant; an insulating layer provided within the region surrounded by the sealant on at least one of the pair of substrates; and an alignment layer provided between the insulating layer and the electro-optical material layer. The region surrounded by the sealant includes an effective display region where display is performed and a peripheral region located between the effective display region and the sealant, and the insulating layer within the peripheral region is formed with a recessed portion to which a material of the alignment layer flows.