LIQUID CRYSTAL DEVICE, OPTICAL SYSTEM, SPATIAL PHASE MODULATOR, AND METHOD OF MANUFACTURING LIQUID CRYSTAL DEVICE

Abstract

A liquid crystal device in one aspect of the present disclosure includes a liquid crystal layer, and an electrode layer configured to form an electric field in the liquid crystal layer. The liquid crystal layer includes a liquid crystal composition in which an organic compound having a property of inhibiting a polymerization reaction caused by light action is added to a liquid crystal mixture as a polymerization inhibitor.

Claims

1. A liquid crystal device comprising: a liquid crystal layer; and an electrode layer configured to create an electric field in the liquid crystal layer, wherein the liquid crystal layer includes a liquid crystal composition in which an organic compound having a property of inhibiting a polymerization reaction caused by light action is added to a liquid crystal mixture as a polymerization inhibitor.

2. The liquid crystal device according to claim 1, wherein the polymerization inhibitor has a property of inhibiting radical polymerization.

3. The liquid crystal device according to claim 1, wherein the liquid crystal mixture includes a liquid crystal compound having a tolan structure, and wherein the polymerization inhibitor inhibits radical polymerization caused by light action to the tolan structure.

4. The liquid crystal device according to claim 1, wherein the liquid crystal composition includes 0.01 wt.% to 20 wt.% of the polymerization inhibitor.

5. The liquid crystal device according to claim 1, wherein the liquid crystal composition includes 0.05 wt.% to 10 wt.% of the polymerization inhibitor.

6. The liquid crystal device according to claim 4, wherein the liquid crystal composition includes 3 wt.% or more of the polymerization inhibitor.

7. The liquid crystal device according to claim 1, wherein the polymerization inhibitor is an organic compound having an aromatic ring structure, and an alkyl group structure having carbon number 3 or greater.

8. The liquid crystal device according to claim 1, wherein the electrode layer comprises: a transparent electrode layer disposed above the liquid crystal layer; and a lower electrode layer disposed below the liquid crystal layer, wherein alignment films, configured to control an initial alignment of liquid crystal molecules in the liquid crystal layer vertically or horizontally, are disposed between the liquid crystal layer and the transparent electrode layer, and between the liquid crystal layer and the lower electrode layer, and wherein the liquid crystal layer is formed as a vertical alignment (VA) liquid crystal layer or a horizontal alignment (HA) liquid crystal layer.

9. The liquid crystal device according to claim 1, wherein the liquid crystal device is created as an LCOS device having the electrode layer and the liquid crystal layer interposed between a silicon substrate and a cover glass.

10. The liquid crystal device according to claim 1, wherein the liquid crystal mixture demonstrates a nematic liquid crystalline property.

11. An optical system comprising: a light source; the liquid crystal device, according to claim 1, configured to receive an input of laser light from the light source; and a controller configured to control the liquid crystal device, wherein the liquid crystal device is controlled by the controller to modulate the laser light and output a modulated laser light.

12. A liquid-crystal-type spatial phase modulator comprising: a transparent solid material layer configured to receive an input of light; a transparent electrode layer disposed below the solid material layer; a first alignment film layer disposed below the transparent electrode layer; a liquid crystal layer disposed below the first alignment film layer; a second alignment film layer disposed below the liquid crystal layer; a lower electrode layer disposed below the second alignment film layer; and a silicon substrate disposed below the lower electrode layer, wherein the transparent electrode layer is an indium tin oxide (ITO) transparent electrode layer, wherein the first alignment film layer and the second alignment film layer are inorganic alignment film layers made of silicon oxide (SiOx), and wherein the liquid crystal layer includes a liquid crystal composition in which an organic compound having a property of inhibiting a polymerization reaction caused by light action is added to a liquid crystal mixture as a polymerization inhibitor.

13. A method of manufacturing a liquid crystal device comprising: creating a liquid crystal composition by adding, to a liquid crystal mixture, an organic compound having a property of inhibiting a polymerization reaction caused by light action; and manufacturing the liquid crystal device that includes a liquid crystal layer having the property of inhibiting a polymerization reaction by using the liquid crystal composition to form a liquid crystal layer.

14. The method of manufacturing liquid crystal device according to claim 13, wherein the organic compound includes a property of inhibiting radical polymerization.

15. The method of manufacturing liquid crystal device according to claim 13, wherein the liquid crystal mixture includes a liquid crystal compound having a tolan structure, and wherein the organic compound has a property of inhibiting radical polymerization caused by light action to the tolan structure.

16. The method of manufacturing liquid crystal device according to claim 13, wherein the liquid crystal composition includes 0.01 wt.% to 20 wt.% of the organic compound.

17. The method of manufacturing liquid crystal device according to claim 13, wherein the liquid crystal composition includes 0.05 wt.% to 10 wt.% of the organic compound.

18. The method of manufacturing liquid crystal device according to claim 16, wherein the liquid crystal composition includes 3 wt.% or more of the organic compound.

19. The method of manufacturing liquid crystal device according to claim 13, wherein an organic compound having an aromatic ring structure and an alkyl group structure having carbon number 3 or greater is added to the liquid crystal mixture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a diagram showing a schematic configuration of a laser processing system.

[0026] FIG. 2 is a sectional view showing an inner structure of a spatial phase modulator.

[0027] FIG. 3 is a flowchart explaining a method of manufacturing the spatial phase modulator.

[0028] FIG. 4 is a graph showing experimental results with respect to an addition of a polymerization inhibitor.

EXPLANATION OF REFERENCE NUMERALS

[0029] 10...laser processing system, 11...light source, 13...beam expanding lens, 15...projection element (spatial phase modulator), 17...controller, 19...imaging lens, 100...spatial phase modulator, 110...silicon substrate, 120...cover glass, 130...transparent electrode layer, 140...first alignment film layer, 150...liquid crystal layer, 160... second alignment film layer, 170...reflection layer, 180...lower electrode layer, 190...circuit layer.

MODE FOR CARRYING OUT THE INVENTION

[0030] Hereinafter, example embodiments of the present disclosure will be explained with reference to the drawings.

[0031] A spatial phase modulator 100 of the present embodiment is configured as an LCOS device that has durability against high-energy light. Particularly, the spatial phase modulator 100 of the present embodiment is configured as an LCOS device designed for a laser processing use.

[0032] In a laser processing system 10, pulsed light having a power with high peak value is emitted. The spatial phase modulator 100, which is used in the laser processing system 10, is thus required to have durability against an input of high-energy pulsed light.

[0033] The laser processing system 10 shown in FIG. 1 irradiates a projection element 15 with pulsed light from a light source 11 through a beam expanding lens 13. The spatial phase modulator 100 is installed in the laser processing system 10 as this projection element 15.

[0034] The spatial phase modulator 100 includes two-dimensionally arranged electrodes corresponding to two or more pixels. The spatial phase modulator 100 is configured to modulate a phase of input light for each pixel by having these electrodes apply voltage to liquid crystal. The spatial phase modulator 100 is controlled by a controller 17 to convert the pulsed light from the light source 11 into phase-modulated light corresponding to an image that should be created on a processing-target surface 20 and output the phase-modulated light.

[0035] A phase-modulated image which corresponds to the output light from the spatial phase modulator 100 is created on the processing-target surface 20 through an imaging lens 19. This phase-modulated image serves to process the processing-target surface 20. By using this laser processing system 10, a two-dimensional image can be created on the processing-target surface 20 by a single shot of the pulsed light.

[0036] As shown in FIG. 2, the spatial phase modulator 100 of the present embodiment includes a cover glass 120, a transparent electrode layer 130, a first alignment film layer 140, a liquid crystal layer 150, a second alignment film layer 160, a reflection layer 170, a lower electrode layer 180, and a circuit layer 190 on a silicon substrate 110.

[0037] The cover glass 120 is the uppermost layer of the spatial phase modulator 100 as a solid material layer that receives an input of light. The pulsed light from the light source 11 is inputted into the cover glass 120. The transparent electrode layer 130 is disposed below the cover glass 120. The first alignment film layer 140, the liquid crystal layer 150, and the second alignment film layer 160 are disposed below the transparent electrode layer 130.

[0038] The first alignment film layer 140 is disposed above and adjacent to the liquid crystal layer 150. The second alignment film layer 160 is disposed below and adjacent to the liquid crystal layer 150. The first alignment film layer 140 and the second alignment film layer 160 are configured as vertical alignment films to control an initial alignment of liquid crystal molecules to be vertical with respect to each layer in the spatial phase modulator 100.

[0039] The liquid crystal layer 150 is disposed between the first alignment film layer 140 and the second alignment film layer 160. The liquid crystal layer 150 is affected by the first alignment film layer 140 and the second alignment film layer 160 and is configured as a vertical alignment (VA) liquid crystal layer, in which the liquid crystal molecules are vertically aligned under an electric-field-free state that is a state without an application of a voltage.

[0040] The reflection layer 170 is disposed below the second alignment film layer 160 and is configured to reflect the pulsed light, which is inputted into the cover glass 120 from above the spatial phase modulator 100 and propagated through the transparent electrode layer 130, the first alignment film layer 140, the liquid crystal layer 150, and the second alignment film layer 160 in this order.

[0041] A reflected light from the reflection layer 170 in response to an input light to the cover glass 120 propagates upwards through the second alignment film layer 160, the liquid crystal layer 150, the first alignment film layer 140, the transparent electrode layer 130, and the cover glass 120 in this order, and then outputted as the phase-modulated light of the input light.

[0042] The lower electrode layer 180 includes the aforementioned electrode for each pixel, and together with the transparent electrode layer 130, receives a drive signal from the controller 17 and, in response, applies a voltage on the liquid crystal layer 150 for each pixel. This voltage application forms an electric field in the liquid crystal layer 150. Due to this formation of the electric field, a phase shift occurs in each pixel in the light passing through the liquid crystal layer 150, which enables phase modulation.

[0043] In the spatial phase modulator 100, a heat generation that cannot be ignored is caused by absorption of high-energy light. The heat generation may cause thermal damage in the spatial phase modulator 100. Thus, each layer of the spatial phase modulator 100 of the present embodiment is formed of materials that help inhibit the thermal damage.

[0044] To inhibit the thermal damage, a material with high thermostability can be selected. Or, a material with good thermal conductivity may be selected to enable fast diffusion of heat. Or, a material with good transmissivity may be selected to inhibit heat generation due to light absorption.

[0045] In the present embodiment, the cover glass 120 is made of sapphire. The heat-proof temperature of sapphire is about 2000° C., which is higher than that of a borosilicate glass, a typical cover glass material. The thermal conductivity of sapphire is about 42 W/mK.

[0046] The transmissivity of sapphire is about 85% or greater in a wavelength band of 400 to 1000 nm. As mentioned above, the cover glass 120 made of sapphire not only has durability against heat generation but also enables efficient diffusion and dissipation of heat to outside of spatial phase modulator 100.

[0047] ds, a wavelength band of the pulsed light, may be from 400 nm to 1000 nm. However, in a case where the applicable band of the spatial phase modulator 100 is expanded or shifted to a wavelength band of ultraviolet ray, the material for the cover glass 120 may be changed to quartz.

[0048] Quartz shows higher transmissivity than sapphire in the ultraviolet-ray region. Quartz however has lower thermal conductivity than sapphire, which is merely about 1 W/mK. The material for the cover glass 120 can thus be selected between sapphire and quartz depending on the applicable band of the spatial phase modulator 100.

[0049] The transparent electrode layer 130 is formed as an ITO (indium tin oxide) transparent electrode layer. ITO is a wide gap semiconductor that has an energy band gap in the ultraviolet region. Considering the function the spatial phase modulator 100 should render, the transparent electrode layer 130 is required to have transmissivity and electric conductivity. Under this condition, it is appropriate to form the transparent electrode layer 130 using ITO.

[0050] Transmissivity of the transparent electrode layer 130 is however not high compared with other layers in the spatial phase modulator 100. In other words, in the transparent electrode layer 130, heat generation is likely to occur in response to receiving the pulsed light. In addition, the heat-proof temperature of the transparent electrode layer 130 is about 600° C. or less.

[0051] This heat generated in the transparent electrode layer 130 is efficiently dissipated to the outside of spatial phase modulator 100 owing to the high thermal conductivity of the cover glass 120. This high thermal conductivity of the cover glass 120 inhibits the thermal damage of the transparent electrode layer 130.

[0052] The first and second alignment film layer 140 and 160 is formed of the inorganic alignment film layer of silicon oxide (SiOx). The heat-proof temperature of a polyimide organic alignment film layer, which is conventionally often used as an alignment film layer, is 400° C. or less.

[0053] Meanwhile, the heat-proof temperature of the inorganic alignment film layer of silicon oxide (SiOx) is about 1000° C., which is higher than the heat-proof temperatures of the transparent electrode layer 130 and the liquid crystal layer 150. Owing to the above, in the present embodiment, it is possible to inhibit a situation where the first and second alignment film layer 140 and 160 are damaged before the transparent electrode layer 130 and the liquid crystal layer 150 are damaged, which disables the spatial phase modulator 100.

[0054] Furthermore, in the present embodiment, the reflection layer 170 that is non-metallic is disposed above the lower electrode layer 180. This inhibits the heat generation in the lower electrode layer 180. The lower electrode layer 180 includes an aluminum or gold electrode as the aforementioned electrode for each pixel.

[0055] More specifically, the reflection layer 170 includes a multi-layer structure of inorganic materials. Examples of the inorganic material include silicon dioxide (SiO.sub.2), titanium oxide (TiO.sub.2 or Ti.sub.2O.sub.3), and magnesium fluoride MgF.sub.2. Heat-proof temperature of the multi-layer structure of these inorganic materials is about 1100° C., which corresponds to melting points of these inorganic materials.

[0056] By using the multi-layer structure of the inorganic materials, it is possible to form the reflection layer 170 having the transmissivity of less than 1%, which enables inhibition of the heat generation in the reflection layer 170.

[0057] In addition, in the present embodiment, to improve the durability of the spatial phase modulator 100 against high-energy light, the liquid crystal layer 150 includes a liquid crystal composition to which a polymerization inhibitor for inhibiting radical polymerization is added.

[0058] The damage of the spatial phase modulator 100 includes those ascribable to heat generation as well as those ascribable to radical polymerization, which is a chemical reaction generated in the liquid crystal layer 150. Radical polymerization is one of polymerization reactions generated in response to light action. Shown below is a structural formula of nematic liquid crystal molecule having a tolan structure.

##STR00001##

[0059] The liquid crystal composition is produced by mixing a plurality of liquid crystal compounds. Generally, liquid crystal compounds are low-molecular organic compounds, which have light sensitivity to irradiation of high-intensity light. The liquid crystal compounds are, for example, low-molecular organic compounds having stiff π-structures, flexible side chains, and polar groups.

[0060] Due to the above, a part of the structures of molecules of the liquid crystal compounds goes into an excited state by receiving the input light; and the liquid crystal compounds generate radicals. The chemical formula below explains the nematic liquid crystal molecule that has radicals generated by light action to the tolan structure.

##STR00002##

[0061] As mentioned above, the liquid crystal layer 150 of the present embodiment is a vertical alignment (VA) liquid crystal layer. A liquid crystal mixture having a nematic liquid crystalline property in a broad range of temperature, including the room temperature, is used to form the liquid crystal layer 150. In some cases, the liquid crystal mixture includes a nematic liquid crystal compound having the tolan structure.

[0062] This liquid crystal layer 150 is damaged by chain reaction of addition of monomers and progress of polymerization with highly active radicals, generated due to an action of the input light, being a chain propagation center. Accordingly, if the active radical can be inactivated by facilitating reaction to the active radical generated by the light action, this chain of polymerization reaction can be inhibited to stop the liquid crystal layer 150 from being damaged by the light action.

[0063] To achieve this, in the present embodiment, an organic compound having a property of inhibiting radical polymerization is added to the liquid crystal mixture as the polymerization inhibitor to generate the liquid crystal composition. This liquid crystal composition forms the liquid crystal layer 150.

[0064] In other words, in the present embodiment, the liquid crystal mixture made by mixing a plurality of liquid crystal compounds is prepared as a main material of the liquid crystal composition as shown in FIG. 3 (S110). The polymerization inhibitor is then prepared as an additive (S120). The liquid crystal composition is then produced by adding the polymerization inhibitor to the liquid crystal mixture (S130). The spatial phase modulator 100 is manufactured such that this liquid crystal composition is used to form the liquid crystal layer 150 (S140).

[0065] In the spatial phase modulator 100 thus produced, the polymerization inhibitor included in the liquid crystal layer 150 reacts with the active radical in the liquid crystal layer 150 and inactivates the active radical. Therefore, in the liquid crystal layer 150, the damage due to the radical polymerization can be inhibited by blocking a chain of the polymerization reaction.

[0066] The polymerization inhibitor can be generated from stable-radical chemical compounds and the like that catch radicals. In the present embodiment, for example, a polymerization inhibitor that is soluble in the liquid crystal mixture and has no reaction to the liquid crystal mixture may be used. In terms of easily being dissolved in the liquid crystal mixture and in terms of not largely changing the physical properties of the liquid crystal composition, an organic compound that has a structure close to the liquid crystal molecule structure can be selected as the polymerization inhibitor.

[0067] More specifically, a favorable molecular structure of the organic compound is one that has a side-chain alkyl group structure in addition to a basic structure of the polymerization inhibitor. Examples of the basic structure of the polymerization inhibitor may include hydroquinone and p-benzoquinone of quinones; o-dinitrobenzene, m-dinitrobenzene, p-dinitrobenzene, 2, 4-dinitrobenzene, 1, 3, 5-trinitrobenzene, 1, 3, 5-trinitroanisole, 1, 3, 5-trinitrotoluene, and dinitrodurene of nitro compounds; o-nitrophenol, m-nitrophenol, p-nitrophenol, 2, 4-dinitrophenol, 2, 4, 6-trinitrophenol, and nitroso of nitrophenols; nitrosobenzene, methyl-α-nitroso isopropyl ketone, phenyl-t-butylnitron of nitrone compound.

[0068] The organic compound in a liquid crystal state has a structure having both an aromatic ring structure, such as benzene ring, and alkyl group. In other words, the organic compound that has a structure close to the liquid crystal molecular structure is a chemical compound having both an aromatic ring structure and an alkyl group structure.

[0069] Specific examples of the organic compound that has a structure close to the liquid crystal molecular structure include 2-dodecylphenol, 2, 6-tert-butyl-p-cresol, tert-butyl hydroquinone, 4-tert-butylpyrocatechol, 2-tert-butyl-1, 4-benzoquinone, 6-tert-butyl-2, 4-xylenol, and 2, 6-di-tert-butylphenol. These example organic compounds has alkyl group having C3, which is carbon number of 3, or more. The aforementioned organic compounds, which include alkyl group with carbon number of 3 or more, are particularly easily dissolved in the liquid crystal mixture and thus are suited for a high-concentrated addition.

[0070] Structural formula of 2-dodecylphenol is shown below.

##STR00003##

[0071] Structural formula of 2, 6-tert-butyl-p-cresol is shown below.

##STR00004##

[0072] Structural formula of tert-butyl hydroquinone is shown below.

##STR00005##

[0073] Structural formula of 4-tert-butyl pyrocatechol is shown below.

##STR00006##

[0074] Structural formula of 2-tert-butyl-1, 4-benzoquinone is shown below.

##STR00007##

[0075] Structural formula of 6-tert-butyl-2, 4-xylenol is shown below.

##STR00008##

[0076] Structural formula of 2, 6-di-tert-butylphenol is shown below.

##STR00009##

[0077] To form the liquid crystal layer 150, one or more of the aforementioned examples of organic compound, which has a structure close to the liquid crystal molecular structure, may be used as the polymerization inhibitor. For example, to form the liquid crystal layer 150, 2-dodecylphenol (molecular formula: C.sub.18H.sub.30O; molecular weight: 262.44) may be used as the polymerization inhibitor. Or, 2, 6-di-tert-butyl-p-cresol (molecular formula: C.sub.15H.sub.24O; molecular weight 220.36) may be used as the polymerization inhibitor.

[0078] Such polymerization inhibitors can effectively inhibit the radical polymerization caused by the light action to the structure of molecules such as the tolan structure. Nevertheless, the polymerization inhibitor should not be limited to these specific examples. Commercially available polymerization inhibitors (also called polymerization blockers, polymerization preventing agents, or anti-polymerization agents) may also be used.

[0079] The aforementioned polymerization inhibitors may be added to the liquid crystal mixture in a range from 0.01 wt.% to 20 wt.%; more specifically, from 0.05 wt.% to 10 wt.%; yet more specifically, from 3 wt.% to 10 wt.%.

[0080] Due to the above, the liquid crystal layer 150 may include the liquid crystal composition containing the polymerization inhibitor in a range from 0.01 wt.% to 20 wt.%; more specifically, from 0.05 wt.% to 10 wt.%; yet more specifically, from 3 wt.% to 10 wt.%. Durability of the liquid crystal layer 150 against high-energy light is particularly improved by adding 3 wt.% or more of the polymerization inhibitor. The amount of the polymerization inhibitor to be added can be determined through experiments and the like to an amount that is optimum for inhibiting damage by radical polymerization while keeping the phase modulation property of the spatial phase modulator 100.

[0081] FIG. 4 shows output light density of light that is inputted to the liquid crystal layer 150 on the horizontal axis, and destruction time on logarithmic scale on the vertical axis. The graph shows, by black dots, a destruction time of the liquid crystal layer 150 with 5 wt.% of the polymerization inhibitor added and, by white dots, a destruction time of a conventional liquid crystal layer with no polymerization inhibitor added. As the graph tells, when high-energy light is inputted to the liquid crystal layer 150, damage of the liquid crystal layer 150 can be effectively inhibited by the addition of the polymerization inhibitor.

[0082] As explained above, the liquid crystal layer 150 in the present embodiment includes the liquid crystal composition, to which the organic compound that has the property of inhibiting the radical polymerization is added. This enables the spatial phase modulator 100 to have high durability against the input of high-energy light.

[0083] In the present embodiment, by selecting materials in consideration of heat generation due to light absorption, the thermal damage in the spatial phase modulator 100 can also be inhibited. Accordingly, it is possible to provide the spatial phase modulator 100 that has high durability not only against damage due to the polymerization reaction but also against thermal damage. Such a spatial phase modulator 100 can form a laser processing system 1 having excellent durability.

[0084] Generally, liquid crystal materials are selected to achieve desired optical performance such as of a response speed and a modulation amount. Altering the selection of the liquid crystal material in consideration of damage leads to a degradation of optical performance. In the present embodiment, damage is inhibited by adding the polymerization inhibitor; therefore, durability against high-energy light can be improved while maintaining the optical performance without altering the liquid crystal material. The technique of the present disclosure is therefore very productive.

[0085] It should be noted that the present disclosure should not be limited to the aforementioned embodiments and may be embodied in various modes. The technique of the present disclosure should not be limited to the application to spatial phase modulators but also can be applied to LCOS devices and liquid crystal devices of different usages.

[0086] The technique of the present disclosure should not be limited to the application to the reflective liquid crystal device as shown in FIG. 2 but also can be applied to transmissive liquid crystal devices. The technique of the present disclosure may also be applied to horizontal alignment (HA) type liquid crystal devices and IPS (In Plane Switching) type liquid crystal devices.

[0087] For example, the technique of the present disclosure may be applied to a liquid crystal device that includes alignment films, which horizontally control the initial alignment of the liquid crystal molecules in the liquid crystal layer, between the liquid crystal layer and the transparent electrode layer and between the liquid crystal layer and the lower electrode layer; and that includes the liquid crystal layer as the horizontal alignment (HA) liquid crystal layer. In other words, the liquid crystal layer 150 of the aforementioned spatial phase modulator 100 may be configured as the horizontal alignment (HA) liquid crystal layer including the alignment films for horizontal alignment as the first and second alignment film layers 140 and 160.

[0088] The technique of the present disclosure includes an idea of forming the liquid crystal composition by adding, to the liquid crystal mixture, the organic compound having a property of inhibiting the polymerization reaction caused by the light action, and then forming the liquid crystal layer by using the liquid crystal composition to manufacture the liquid crystal device that includes the liquid crystal layer having a property of inhibiting the polymerization reaction caused by the light action. Therefore, the liquid crystal layer 150 may also be formed by the liquid crystal composition to which the polymerization inhibitor that is not only against the radical polymerization but also against other polymerization reaction caused by the light action is added.

[0089] Functions of one element in the aforementioned embodiments may be achieved by two or more elements. Functions of two or more elements in the aforementioned embodiments may be achieved by one element. A part of the configuration of the aforementioned embodiments may be omitted. Any and all modes included in the technical ideas identified by the languages recited in the claims are embodiments of the present disclosure.