GB2484068A - Liquid crystal coating film, for producing birefringent component - Google Patents

Liquid crystal coating film, for producing birefringent component Download PDF

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Publication number
GB2484068A
GB2484068A GB1015960.6A GB201015960A GB2484068A GB 2484068 A GB2484068 A GB 2484068A GB 201015960 A GB201015960 A GB 201015960A GB 2484068 A GB2484068 A GB 2484068A
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GB
United Kingdom
Prior art keywords
liquid crystal
coating film
flexible sheet
crystal polymer
polymer layer
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Granted
Application number
GB1015960.6A
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GB201015960D0 (en
GB2484068B (en
Inventor
Jonathan Harrold
Graham John Woodgate
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AU Optronics Corp
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AU Optronics Corp
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Publication date
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Priority to GB1015960.6A priority Critical patent/GB2484068B/en
Priority to TW099136783A priority patent/TWI498644B/en
Publication of GB201015960D0 publication Critical patent/GB201015960D0/en
Priority to CN201010570548.1A priority patent/CN102135637A/en
Publication of GB2484068A publication Critical patent/GB2484068A/en
Application granted granted Critical
Publication of GB2484068B publication Critical patent/GB2484068B/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3083—Birefringent or phase retarding elements
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/13363—Birefringent elements, e.g. for optical compensation
    • G02F1/133636—Birefringent elements, e.g. for optical compensation with twisted orientation, e.g. comprising helically oriented LC-molecules or a plurality of twisted birefringent sublayers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/55—Liquid crystals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/42—Polarizing, birefringent, filtering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/706—Anisotropic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/18—Cellulose, modified cellulose or cellulose derivatives, e.g. viscose
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2329/00—Polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals
    • B32B2329/04—Polyvinylalcohol
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B32B2333/04—Polymers of esters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
    • B32B2457/202—LCD, i.e. liquid crystal displays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B32B37/025—Transfer laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/133305—Flexible substrates, e.g. plastics, organic film
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/133371—Cells with varying thickness of the liquid crystal layer
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1337—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers
    • G02F1/133711—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers by organic films, e.g. polymeric films
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1337—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers
    • G02F1/13378—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers by treatment of the surface, e.g. embossing, rubbing or light irradiation
    • G02F1/133784—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers by treatment of the surface, e.g. embossing, rubbing or light irradiation by rubbing

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Nonlinear Science (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Mathematical Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Polarising Elements (AREA)
  • Laminated Bodies (AREA)
  • Liquid Crystal (AREA)

Abstract

The coating film comprises a liquid crystal (LC) polymer 120 deposited on a flexible sheet 110. The part of the LC layer remote from the flexible sheet has a non-flat surface. The LC polymer is converted from a crystalline phase to a nematic phase and back to a crystalline phase. The coating film 100 is applied onto an object (300, figure 9) when the LC is in the nematic phase, with the LC between the flexible sheet and the object. The nematic LC polymer is cured, preferably be means of electromagnetic radiation. The flexible sheet is preferably a polyethylene terephthalate (PET), polyvinyl alcohol (PVA), polycarbonate or cellulose triacetate film, which preferably has an intrinsic alignment property, enhanced by rubbing. Vacuum degassing is preferably used to remove air bubbles.

Description

Liquid Crystal Coating Film, Method for Manufacturing the Same and Method for Manufacturing Birefringent Liquid Crystal Component The present disclosure relates to optical components. More particularly, the present disclosure relates to liquid crystal optical components.
to Surface relief birefringent optical components are described for example in WO-03/015424 and WO-2005/006056. A birefringent microlens array is formed from a surface relief interface between an isotropic material and an aligned birefringent liquid crystal material. Light of a first linear polarization state passing through the device sees a first refractive index step at the surface is relief interface between the isotropic material and the birefringent liquid crystal material, whereas light of a second orthogonal linear polarization state sees a second, different refractive index step at the interface.
The surface relief birefringent optical components described above may be made in accordance with the manufacturing method disclosed in WO-2008/0621 88, which is hereby incorporated herein by reference. In WO-2008/062188, the nematic liquid crystal polymer (N-LOP) is dispensed in the gap between the flexible sheet and the surface relief structure and then is cured. However, the manufacturing method disclosed in WO-2008/062188 has a number of difficulties.
1. The liquid crystal polymer has to keep in the nematic phase for a long time, so it has high probability of premature thermal cure.
2. A crystallized liquid crystal polymer powder may be introduced into the manufacturing environment. It has high probability of contamination of equipment by the crystallized liquid crystal polymer powder.
3. A heated nozzle system for dispensing the nematic liquid crystal polymer is required.
It would be desirable to provide a manufacturing method in which at least some of these difficulties are alleviated.
One aspect of the present invention is to provide a liquid crystal coating film for coating a liquid crystal polymer layer onto an object.
According to one embodiment of the present invention, a liquid crystal coating film includes a flexible sheet and a liquid crystal polymer layer. The flexible sheet has a top surface. The liquid crystal polymer layer is disposed on the top surface of the flexible sheet, wherein the liquid crystal polymer layer has a non-flat top and is in a crystalline phase.
Another aspect of the present invention is to provide a method for using the liquid crystal coating film to manufacture a birefringent liquid crystal component.
According to another embodiment of the present invention, a method for manufacturing a birefringent liquid crystal component includes the following steps. A liquid crystal coating film is formed. The liquid crystal polymer layer of the liquid crystal coating film is converted from a crystalline phase to a nematic phase. The liquid crystal coating film is applied onto an object to be coated with the liquid crystal polymer layer of the liquid crystal coating film in the nematic phase sandwiched between the flexible sheet of the liquid crystal coating film and the object. The liquid crystal polymer layer of the liquid crystal coating film is cured after the liquid crystal coating film is applied onto the object.
Yet another aspect of the present invention is to provide a method for manufacturing the liquid crystal coating film.
According to yet another embodiment of the present invention, a method for manufacturing a liquid crystal coating film includes the following steps. A flexible sheet having a top surface is formed. A liquid crystal polymer material in a crystalline phase is applied to the top surface of the flexible sheet. The liquid crystal polymer material is converted to a nematic phase. The liquid crystal polymer material is converted from the nematic phase to the crystalline phase.
The foregoing embodiments of the present invention have at least the
following advantages over the known prior art.
(1) The time at which the liquid crystal polymer is in the nematic phase is minimized, so that the probability of premature thermal cure is reduced.
(2) A crystallized liquid crystal polymer powder is not introduced into the manufacturing environment, thus reducing the probability of contamination of equipment by the crystallized liquid crystal polymer powder.
(3) The liquid crystal coating film can be manufactured at a different location than where the birefringent liquid crystal component is manufactured, thereby increasing flexibility of manufacturing environment design and reducing overall cost.
(4) A heated nozzle system for dispensation of the nematic liquid crystal polymer is not required.
In the drawings Fig. 1 is a side view of a liquid crystal coating film according to one embodiment of the present invention.
Figs. 2-6 are side views of a method for manufacturing the liquid crystal coatingfilmofFig. 1.
Figs. 7-11 are side views of a method for using the liquid crystal coating film of Fig. I to manufacture a birefringent liquid crystal component.
is In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
In other instances, well-known structures and devices are schematically depicted in order to simplify the drawings.
Fig. 1 is a side view of a liquid crystal coating film 100 according to one embodiment of the present invention. As shown in Fig. 1, the liquid crystal coating film 100 includes a flexible sheet 110 and a liquid crystal polymer layer 120. The flexible sheet 110 has a top surface 112. The liquid crystal polymer layer 120 is disposed on the top surface 112 of the flexible sheet 110, wherein the liquid crystal polymer layer 120 has a non-flat top and is in a crystalline phase.
Figs. 2-6 are side views of a method for manufacturing the liquid crystal coating film 100 of Fig. 1. The method for manufacturing the liquid crystal coating film 100 includes the following steps: (1) forming a flexible sheet 110 having a top surface 112 (shown in Fig. 2); (2) applying a liquid crystal polymer material 123 in a crystalline phase to the top surface 112 of the flexible sheet 110 (shown in Fig. 3); io (3) converting the liquid crystal polymer material 123 to a nematic phase (shown in Fig. 4); (4) optionally removing air bubbles 125 from the liquid crystal polymer material 123 when the liquid crystal polymer material 123 is in the nematic phase (shown in Fig. 5); (5) converting the liquid crystal polymer material 123 from the nematic phase to the crystalline phase (shown in Fig. 6).
In Fig. 2, the flexible sheet 110 having the top surface 112 is formed.
The material of the flexible sheet 110 may be a polymer, for example polyethyleneterephthalate (PET), polyvinylalcohol (PVA), polycarbonate (PC), triacetyl-cellulose (TAC), or any mixture thereof.
The top surface 112 of the flexible sheet 110 may be provided with a liquid crystal alignment property. The material of the flexible sheet 110 may be chosen to provide the liquid crystal alignment property intrinsically. The top surface 112 of the flexible sheet 110 may be rubbed to make the liquid crystal alignment property substantially uniform. As shown in Fig. 2, the liquid crystal alignment property may be formed on the top surface 112 of the flexible sheet 110, for example, by rubbing with a rubbing cloth mounted on a spinning drum or rubbing the alignment layer which is formed on the flexible sheet 110 in advance, by a spinning roller.
In Fig. 3, the liquid crystal polymer material 123 in the crystalline phase is applied to the top surface 112 of the flexible sheet 110. The liquid crystal polymer material 123 may be Ultraviolet (UV) curable. The liquid crystal polymer material 123 may be, for example, RM257 or RMM34c from Merck, or LC242, LC270 or LC1057 from BASF.
To In Figs. 4-5, the liquid crystal polymer material 123 is converted to a nematic phase. The liquid crystal polymer material 123 can be heated to a process temperature, for example, by means of a heater pad or by means of placing the whole structure in an oven at a desired temperature, say 90 degrees Celsius. The process temperature is typically above the crystalline to nematic is transition temperature of the liquid crystal polymer material 123 but low enough to minimize thermal cure of the liquid crystal polymer material 123.
In Fig. 5, air bubbles 125 may be removed from the liquid crystal polymer material 123 when the liquid crystal polymer material 123 is in the nematic phase. This step can be performed by, for example, vacuum degassing.
In Fig. 6, the liquid crystal polymer material 123 is converted from the nematic phase to the crystalline phase. In this step, the liquid crystal polymer material 123 is cooled below the crystalline to nematic transition temperature of the liquid crystal polymer material 123. In this way, the liquid crystal polymer material 123 can be crystallized and becomes the liquid crystal polymer layer 120 for storage purpose.
Surface tension is responsible for the shape of the liquid crystal polymer layer 120. The surface tension effect on the liquid crystal polymer material 123 can result in the liquid crystal polymer layer 120 having the non-flat top. In the present embodiment, the non-flat top may be curve shaped or dome shaped.
Figs. 7-11 are side views of a method for using the liquid crystal coating film 100 of Fig. I to manufacture a birefringent liquid crystal component. The method for manufacturing the birefringent liquid crystal component includes the following steps: (1) converting the liquid crystal polymer layer 120 of the liquid crystal io coating film 100 from the crystalline phase to the nematic phase (shown in Fig. 7); (2) optionally removing air bubbles 125 from the liquid crystal polymer layer 120 of the liquid crystal coating film 100 when the liquid crystal polymer layer 120 of the liquid crystal coating film 100 is in the nematic phase (shown in Fig. 8); (3) applying the liquid crystal coating film 100 onto an object 300 to be coated with the liquid crystal polymer layer 120 of the liquid crystal coating film in the nematic phase sandwiched between the flexible sheet 110 of the liquid crystal coating film 100 and the object 300 (shown in Fig. 9); (4) curing the liquid crystal polymer layer 120 of the liquid crystal coating film 100 after the liquid crystal coating film 100 is applied onto the object 300 (shown in Fig. 10); and (5) optionally removing the flexible sheet 110 from the liquid crystal polymer layer 120 (shown in Fig. 11).
In Fig. 7, the liquid crystal polymer layer 120 of the liquid crystal coating film 100 is converted from the crystalline phase to the nematic phase. This step can be performed by heating the liquid crystal polymer layer 120 to a process temperature, for example, by means of a heater pad, by means of blowing hot air across the surface of the liquid crystal polymer layer 120, or by means of placing the liquid crystal coating film 100 in an oven at the desired temperature, say 90 degrees Celsius. The process temperature is typically above the crystalline to nematic transition temperature of the liquid crystal polymer layer 120 but low enough to minimize thermal cure of the liquid crystal polymer layer 120.
In Fig. 8, air bubbles 125 may be removed from the liquid crystal polymer layer 120 when the liquid crystal polymer layer 120 is in the nematic phase.
This step can be performed by, for example, vacuum degassing.
In Fig. 9, the liquid crystal coating film 100 is applied onto the object 300 is by draping the flexible sheet 110 over the object 300 by an application bar 400 which moves in contact with the exterior surface of the flexible sheet 110 over the flexible sheet 110. In this way, the liquid crystal polymer layer 120 (in the nematic phase) can be applied into the gap between the object 300 and the flexible sheet 110 in front of the application bar 400 as the flexible sheet 110 is draped on. Thus, the application bar 400 squeezes the liquid crystal polymer layer 120 to a controlled thickness governed by the height of the application bar 400. Thus, the surface of the liquid crystal polymer layer 120 opposite from the object 300 is planar.
The object 300 can be a surface relief optical component. The surface relief optical component 300 includes a substrate 310, a surface relief layer 320, and an alignment layer 330. The substrate 310 may be made of glass or a polymer. The surface relief layer 320 is formed on the surface of the substrate 310. The surface relief layer 320 comprises a material which in this embodiment is isotropic and a polymer. The outer surface of the surface relief layer 320 is shaped with a surface relief structure, in this case comprising an array of cylindrical lens surfaces. The alignment layer 330 is disposed on the surface relief structure of the surface relief layer 320 to provide the surface relief structure of the surface relief layer 320 with a liquid crystal alignment property.
The surface relief optical component 300 described above may be made io in accordance with the manufacturing method disclosed in WO-2008/062188, which is hereby incorporated herein by reference.
The surface relief optical component 300 can be heated in this step, for example, by means of a heater pad 500, by means of blowing hot air across the surface of the surface relief optical component 300, or by means of placing the surface relief optical component 300 in an oven at the desired temperature, say degrees Celsius. The process temperature is typically above the crystalline to nematic transition temperature of the liquid crystal polymer layer 120 but low enough to minimize thermal cure of the liquid crystal polymer layer 120. If the liquid crystal polymer layer 120 is made of a material which supercools, the processing temperature may be below the crystalline to nematic transition temperature. With suitable materials, this can include room temperature.
The application bar 400 may be a member having a variety of forms.
The application bar 400 may have a circular cross section for example and may optionally have an outer coating, such as a rubber material. Alternatively, the application bar 400 may have a non-circular cross section, such as a rubber wiper. The application bar 400 may roll or slide as shown by arrows A and B respectively across the surface of the flexible sheet 110, thus trapping the liquid crystal polymer layer 120 between the flexible sheet 110 and the object 300.
The direction of the application bar 400 is shown in Fig. 9 as orthogonal to the geometric axis of the cylindrical lens surfaces. However, in the case of such elongate structures, the direction of the application bar 400 can be parallel to the geometric axis of the cylindrical lens surfaces, so that the material can flow uniformly down the channels without trapping air bubbles.
The orientation of the flexible sheet 110 with respect to the alignment layer 330 is selected to provide a desired degree of twist between the alignment directions of the flexible sheet 110 and the alignment layer 330. This adjusts the twist angle of the liquid crystal director within the liquid crystal polymer layer after curing as described below. The alignment direction on the alignment layer 330 may be parallel to the geometric axis of the cylindrical lens surfaces is and at an angle of 135° to the alignment direction on the flexible sheet 110.
Alternative alignment directions may be used depending on the requirements of the optical architecture.
After the liquid crystal polymer layer 120 is applied into the gap between the object 300 and the flexible sheet 110, the whole structure may be left to anneal residual disclinations and then be cooled to a lower temperature to increase the birefringence of the liquid crystal polymer layer 120 and to increase its viscosity during cure or to tune the refractive index of the ordinary component to that of the substrate.
In Fig. 10, the liquid crystal polymer layer 120 is cured into a solid film by means of actinic radiation such as electromagnetic (e.g. ultraviolet) radiation from a light source 600. The ultraviolet lamp may be filtered to remove wavelength components that may adversely affect the liquid crystal polymer layer 120 through absorption. The flexible sheet 110 enables the liquid crystal polymer layer 120 to be of the type, whose cure is inhibited by the presence of oxygen without the need for an inert gas blanket, thus reducing cost and complexity of the apparatus.
When the liquid crystal polymer layer 120 is curable by electromagnetic radiation, the flexible sheet 110 may be transparent to that electromagnetic radiation, and the step of curing the liquid crystal polymer layer 120 is performed by applying the electromagnetic radiation through the flexible sheet 110.
In Fig. 11, the flexible sheet 110 is removed from the liquid crystal polymer layer 120. In this embodiment, the material of the flexible sheet 110 is selected to be sufficiently flexible to allow removal from the cured liquid crystal is polymer layer 120 by peeling. As such it is more flexible than the substrate 310. Alternatively, the flexible sheet 110 may have similar flexibility to the substrate 310. To optimize delamination performance, the adhesion of the cured liquid crystal polymer layer 120 to the flexible sheet 110 should be less than the adhesion at interfaces of the cured liquid crystal polymer layer 120 to the alignment layer 330, the alignment layer 330 to the surface relief layer 320 and the surface relief layer 320 to the substrate 310.
The flexible sheet 110 may be used as a protection film prior to device assembly to remove the need for a cleaning step after processing. Therefore, a further protective film is not required after processing. To allow the flexible sheet 110 to serve as a protective layer, the flexible sheet 110 may be removed at a later time after shipping and subsequent handling. Such a step avoids the need to clean the surfaces after fabrication and prior to device assembly, reducing cost and potential damage of the surface.
It may be possible to re-use the flexible sheet 110 after delamination, although typically this material would be re-processed or disposed of.
Alternatively, the flexible sheet 110 may have a well defined birefringence characteristic, and may be used as an additional waveplate in an optical structure, for example to increase the viewing angle of a separate polarization switching element. In this case, the flexible sheet 110 may not be removed from the liquid crystal polymer layer 120.
In this way, the time at which the liquid crystal polymer layer 120 is in the nematic phase is minimized since the liquid crystal polymer layer 120 is in the crystalline phase for storage. When the liquid crystal polymer layer 120 is converted to the nematic phase, the liquid crystal polymer layer 120 is immediately applied onto the object 300 and then cured. Therefore, the probability of premature thermal cure is reduced.
Furthermore, the liquid crystal polymer is introduced into the manufacturing environment by the liquid crystal coating film 100. A crystallized liquid crystal polymer powder is not introduced into the manufacturing environment1 thus reducing the probability of contamination of equipment by the liquid crystal polymer powder.
In addition, the liquid crystal coating film 100 can be manufactured at a different location than where the birefringent liquid crystal component is manufactured, thereby increasing flexibility of manufacturing environment design and reducing overall cost.
Moreover, a heated nozzle system for dispensation of the nematic liquid crystal polymer is not required, thereby reducing overall cost further.
All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Claims (25)

  1. CLAIMS1. A liquid crystal coating film comprising: a flexible sheet having a top surface; a liquid crystal polymer layer disposed on the top surface of the flexible sheet, wherein the liquid crystal polymer layer has a non4lat top and is in a crystalline phase.
  2. 2. The liquid crystal coating film of claim 1, wherein the liquid crystal polymer layer is curable by electromagnetic radiation when the liquid crystal to polymer layer is in a nernatic phase.
  3. 3. The liquid crystal coating film of claim 2, wherein the flexible sheet is transparent to the electromagnetic radiation.is
  4. 4. The liquid crystal coating film of claim 1, wherein the material of the flexible sheet is a polymer.
  5. 5. The liquid crystal coating film of claim 1, wherein the material of the flexible sheet comprises polyethyleneterephthalate, polyvinylalcohOl, polycarbonate, triacetyl-cellulose or any mixture thereof.
  6. 6. The liquid crystal coating film of claim 1, wherein the top surface of the flexible sheet is provided with a liquid crystal alignment property.
  7. 7. The liquid crystal coating film of claim 1, wherein the top surface of the flexible sheet is provided with a liquid crystal alignment property by an intrinsic property of the material of the flexible sheet.
  8. 8. The liquid crystal coating film of claim, wherein the top surface of the flexible sheet is rubbed to form a substantially uniform liquid crystal alignment property.
  9. 9. A liquid crystal coating film substantially as hereinbefore described, io having reference to the accompanying drawings.
  10. 10. A method for manufacturing a birefringent liquid crystal component, the method comprising: forming a liquid crystal coating film as in any one of claims 1-9; is converting the liquid crystal polymer layer of the liquid crystal coating film from a crystalline phase to a nematic phase; applying the liquid crystal coating film onto an object to be coated with the liquid crystal polymer layer of the liquid crystal coating film in the nematic phase sandwiched between the flexible sheet of the liquid crystal coating film and the object; and curing the liquid crystal polymer layer of the liquid crystal coating film after the liquid crystal coating film is applied onto the object.
  11. 11. The method of claim 10, further comprising: removing air bubbles from the liquid crystal polymer layer of the liquid crystal coating film when the liquid crystal polymer layer of the liquid crystal coating film is in the nematic phase.
  12. 12. The method of claim 10, further comprising: vacuum degassing the liquid crystal polymer layer of the liquid crystal coating film when the liquid crystal polymer layer of the liquid crystal coating film is in the nematic phase.
  13. 13. A method for manufacturing a birefringent liquid crystal component substantially as hereinbefore described, having reference to the accompanying drawings.
  14. 14. A method for manufacturing a liquid crystal coating film, the method is comprising: forming a flexible sheet having a top surface; applying a liquid crystal polymer material in a crystalline phase to the top surface of the flexible sheet; converting the liquid crystal polymer material to a nematic phase; and converting the liquid crystal polymer material from the nematic phase to the crystalline phase.
  15. 15. The method of claim 14, wherein the step of converting the liquid crystal polymer material to the nematic phase comprises: heating the liquid crystal polymer material above the crystalline to nematic transition temperature of the liquid crystal polymer material.
  16. 16. The method of claim 14, wherein the step of converting the liquid crystal polymer material from the nematic phase to the crystalline phase comprises: cooling the liquid crystal polymer material below the crystalline to nematic transition temperature of the liquid crystal polymer material.
  17. 17. The method of claim 14, further comprising: rubbing the top surface of the flexible sheet to form a substantially uniform liquid crystal alignment property.
  18. 18. The method of claim 14, wherein the material of the flexible sheet is a is polymer.
  19. 19. The method of claim 14, wherein the material of the flexible sheet comprises polyethyleneterephthalate, polyvinylalcohol, polycarbonate, triacetyl-cellulose or any mixture thereof.
  20. 20. The method of claim 14, wherein the top surface of the flexible sheet is provided with a liquid crystal alignment property by an intrinsic property of the material of the flexible sheet.
  21. 21. The method of claim 14, wherein the liquid crystal polymer material is curable by electromagnetic radiation when the liquid crystal polymer material is in the nematic phase.
  22. 22. The method of claim 21, wherein the flexible sheet is transparent to the electromagnetic radiation.
  23. 23. The method of claim 14, further comprising: removing air bubbles from the liquid crystal polymer material when the io liquid crystal polymer material is in the nematic phase.
  24. 24. The method of claim 14, further comprising: vacuum degassing the liquid crystal polymer material when the liquid crystal polymer material is in the nematic phase.
  25. 25. A method for manufacturing a liquid crystal coating film substantially as hereinbefore described, having reference to the accompanying drawings.
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TW099136783A TWI498644B (en) 2010-09-22 2010-10-27 Method for manufacturing birefringent liquid crystal component
CN201010570548.1A CN102135637A (en) 2010-09-22 2010-11-26 Liquid crystal transfer film and method of making liquid crystal transfer film and birefringence liquid crystal elements

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WO2001029148A1 (en) * 1999-10-19 2001-04-26 Rolic Ag Topologically structured polymer coating
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WO2008138512A2 (en) * 2007-05-10 2008-11-20 Leonhard Kurz Stiftung & Co. Kg Method for the production of a crosslinked liquid crystal layer, and apparatus for carrying out said method
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WO2001029148A1 (en) * 1999-10-19 2001-04-26 Rolic Ag Topologically structured polymer coating
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