Sealed Liquid Crystal Package Without Sealant for Uniform Smart Windows
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Solution Overview
Problem
Conventional liquid crystal windows face issues with product defects due to gap non-uniformity and sealant tears, and increased manufacturing costs from using separate substrates for conductive layers, which affect transmittance and thickness.
Innovation Solution
A liquid crystal package with a sealed structure without a sealant, featuring a conductive layer directly formed on a polarizing plate, reducing the need for additional substrates and enhancing transmittance by minimizing stack thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sealant is included to provide a space with the liquid crystal layer, then the liquid crystal layer can be formed, but product defects such as gap non-uniformity or sealant tear occur
Solution Approach 1:
The patent removes the sealant component from the conventional liquid crystal window structure. By extracting the sealant and its associated sealing process, the invention eliminates the source of sealant tears and gap non-uniformity, achieving both manufacturing precision and product reliability without this problematic element
Solution Approach 2:
The patent merges the functions of the sealant and the conductive layer by forming the conductive layer directly on the substrate that also serves as the structural boundary. This integration eliminates the need for a separate sealant layer while maintaining both the sealing function and the electrical functionality, thereby preventing defect formation
2Ease of operation
If a separate or additional substrate is included to form a conductive layer, then the liquid crystal can be driven, but manufacturing costs increase and the thickness of the stack increases
Solution Approach 1:
The patent combines the substrate structural function with the conductive layer function by forming the conductive layer directly on the substrate surface. This merging eliminates the need for a separate additional substrate, thereby reducing manufacturing process complexity and final product thickness while maintaining liquid crystal driving capability
Solution Approach 2:
The substrate is given multiple functions: it serves as both the structural support element and the base for the conductive layer. This multi-functionality approach eliminates the need for separate components, simplifying the manufacturing process and reducing overall device complexity
3Ease of operation
If a separate or additional substrate is included to form a conductive layer, then the conductive layer can be formed, but the transmittance changes due to occurrence of phase difference
Solution Approach 1:
By merging the conductive layer formation directly on the substrate, the patent eliminates additional optical interfaces that would cause phase differences. This integration maintains better optical transparency and light transmittance while still providing the necessary conductive functionality for liquid crystal operation
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 solution prevents product defects and reduces manufacturing costs while improving transmittance and flexibility in liquid crystal windows, making them suitable for smart windows in vehicles and buildings.
Implementation Method 1
a variable transmittance optical stack capable of changing the transmittance of light when a voltage is applied has been developed
Data Source
Figure 1~3B
Figure 3C
Figure 4~5
AI summary
A liquid crystal package and a manufacturing method for the same, and an optical stack including the same, and a smart window including the same are proposed. The liquid crystal package includes a first protective film, a first alignment film formed on one surface of a first protective film, a second protective film opposing the first protective film, a second alignment film formed on one surface of the second protective film, and opposing the first alignment film, and a liquid crystal layer provided between the first alignment film and the second alignment film, and has a sealed structure with an outer circumferential surface thereof sealed.