Transmittance-Variable Device Spacer Fixation
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Solution Overview
Problem
Transmittance-variable devices experience scratches and orientation defects due to external forces, leading to light leakage and reduced yield during the manufacturing process, particularly when spacers are not properly fixed to the substrates.
Innovation Solution
A transmittance-variable device design that includes a polarization layer and a transmittance-variable layer with spacers, such as ball or column spacers, fixed to the surface of the first base layer opposite to the polarization layer, maintaining a gap with a second base layer and incorporating a light modulating material, which prevents spacer movement and subsequent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacers are not fixed to the substrate, then the alignment film is vulnerable to external forces causing indentation and orientation defects, but fixing spacers to one substrate only creates instability when external forces are applied
Solution Approach 1:
The invention divides the spacer fixation system into two independent parts: one substrate has spacers fixed to it, while the other substrate has spacers embedded in its alignment film. This segmentation ensures that each substrate independently supports the cell gap, preventing relative movement and maintaining alignment film quality under external forces.
2Ease of manufacture
If heat treatment is performed after cell manufacturing, then the cell is preconditioned, but substrate deformation induces scratches on the alignment film
Solution Approach 1:
The invention embeds spacers in the alignment film before heat treatment, creating a cushioning effect that absorbs and distributes the stress from substrate deformation during preconditioning. This prevents the alignment film from being scratched while still allowing the necessary heat treatment to occur.
3Device complexity
If spacers are fixed to only one substrate, then the cell assembly is simpler, but external forces cause spacer movement and light leakage
Solution Approach 1:
The invention segments the spacer support function across both substrates: one substrate provides mechanical support through fixed spacers, while the other substrate's alignment film embeds spacers to provide additional support. This dual-support segmentation prevents spacer movement and light leakage without significantly complicating the assembly process.
Data Source
AI summary
A transmittance-variable layer and a transmittance-variable device including the same are disclosed herein. In some embodiments, a transmittance-variable device includes a polarization layer and a transmittance-variable layer disposed on the polarization layer, wherein the transmittance-variable layer includes a first base layer disposed on the polarization layer and a spacer fixed on a surface of the first base layer opposite to the polarization layer, and a second base layer facing the first base layer and spaced apart from the first base layer by the first spacer, wherein the first spacer maintains a gap between the first and second base layers, and a first light modulating material disposed in the gap.