Field of the invention
The present invention relates to methods for manufacturing photonic devices and to
photonic devices manufactured by such methods. The invention has particular, but not
exclusive, application to the manufacture of liquid crystal laser devices.
Related art
Liquid crystal (LC) materials are a class of functional photonic materials. LC materials
contain molecules which have a tendency to self-organize along an optical axis. The
way in which the molecules in LC materials align dictates the optical properties of the LC
material. For example, chiral liquid crystals have a tendency to self-organize into a
helicoidal arrangement around an optical axis. Due to the birefringence of the material,
this helicoidal arrangement results in a periodic variation of the refractive index along the
optical axis. For suitable periodicities, this gives rise to a photonic band-gap for visible
wavelengths of circularly polarized light.
The optical properties of chiral LC materials make them suitable for applications ranging
from bistable displays to lasers. Incorporation of an organic laser dye, as the light
harvester or gain medium, into the optical cavity can lead to laser emission at the
photonic band-edges. Laser devices built based on these materials are characterised by
very low cost manufacturing, small size and selectable wavelength of emission, currently
in the range 400 nm to 850 n (See References [4] and [2]).
Applications of achiral LC materials include conventional flat-panel displays (nematic
LCDs), variable retarders and SLMs.
US201 1/0097557 discloses the manufacture of security features, e.g. for bank notes, in
which a poiymerisab!e LC material is printed onto a solid PVA layer. The PVA layer is
unrubbed but is found to promote alignment for certain LC materials.
Conventional semiconductor lasers used in most modern laser systems are solid-state
devices that are typically manufactured using a complex process involving a combination
of deposition, etching and photolithographic steps on high quality single crystal
semiconductor wafers. Such conventional lasers cannot be manufactured using
relatively low cost printing technologies such as bar coating or inkjet printing, for example.
It has previously been shown in References [ 1 1] and [12] that printable emulsion-based
LC laser systems can be deposited on a wide variety of substrates including, for
example, glass, plastic, metal or paper. These documents describe deposition of a LC
lasing medium onto suitable substrates using emulsified samples and a simple barcoating
process. In these disclosures, the liquid crystal and laser dye composition were
emulsified in a continuous phase of PVA, this emulsion then being applied to the
substrate. Subsequent drying of, and inferfacial interaction with, the continuous phase
causes advantageous stresses to be applied to the LC droplets, assisting in the
development of suitable alignment of the LC molecules.
SUMMARY OF THE INVENTION
The present inventors have found that although the approach described by References
[ 1 1] and [12] provides a simple fabrication process, the approach has some
disadvantages. The individual LC droplets are polydisperse in terms of size, typically
with diameters in the range of tens to hundreds of microns. This has an effect on the
quality of the laser emission. Furthermore, the droplets are locally randomly distributed
in the continuous phase. Therefore the approach used in References [ 1 1] and [12] does
not allow accurate positioning of individual droplets, with the consequence that the
spatial position of the emission of light from the device cannot be accurately controlled.
Accordingly, the present inventors attempted to overcome the above disadvantages by
depositing patterns of LC lasing medium. The present inventors found that it is indeed
possible to produce a required pattern of deposits of LC lasing medium, for example by
Inkjet printing. However, the present inventors have found that direct deposition of the
LC lasing medium onto clean, dry surfaces fails to produce a suitable degree of
alignment of the LC molecules (for example, a suitable alignment for many devices that
use chiral LC materials is one in which the chiral LC helical axis is aligned perpendicular
to the substrate).
Control of alignment within LC materials is known to be important to allow the desired
optical properties of the LC material for a particular application to be obtained. For
example, flat-panel display devices comprising nematic LC require a uniform direction of
ihe LC director i.e. alignment of the LC material, for the display to function. For example,
lack of uniform alignment within a deposited LC material for use as a lasing medium can
result in multi-mode laser emission, or even no laser emission,,which is typically
undesirable.
The present invention has been devised in order to address at least one of the above
problems. Preferably, the present invention reduces, ameliorates, avoids or overcomes
at least one of the above problems.
In a general aspect of the invention, the present inventors have found that it is
advantageous to deposit a liquid crystal (LC) material onto a flowable layer of material
that is substantially immiscible with the LC material. Furthermore, the present inventors
have found that further advantages can be achieved when, on impact of the LC material,
the flowable layer of material shapes the LC material with the result of promoting
alignment of molecules in the LC material.
In a first preferred aspect, the present invention provides a method of producing photonic
devices, such as lasers, or optical features by depositing liquid crystal (LC) materials in
one or more discrete regions on surfaces.
In a second preferred aspect, the present invention provides a method of manufacturing
a photonic device, the method comprising the steps of:
(i) providing an aliquot of a liquid crystal (LC) material of volume V, volume V being
the same volume as that of a sphere of diameter D 1; and
(ii) depositing the aliquot onto the surface of a flowable material layer to form a liquid
crystal deposit, the flowable material and the LC material being substantially immiscible,
wherein the liquid crystal deposit adopts a deformed shape relative to the shape of the
aliquot due to interaction with the flowable material layer, the liquid crystal deposit having
a maximum length L1, measured in a direction parallel to the flowable material layer
surface before deposition, wherein L 1 is greater than D1.
In a third preferred aspect, the present invention provides a photonic device obtained by
or obtainable by the method of the first or second aspect.
In a fourth preferred aspect, the present invention provides a laser device obtained by or
obtainable by the method of the first or second aspect.
n a fifth preferred aspect, the present invention provides a photonic device having at
least one liquid crystal (LC) material deposit formed on an underlayer, the underiayer
having an underlayer surface surrounding the LC material deposit, wherein the liquid
crystal deposit has a maximum length L2, measured in a direction parallel to the
underlayer surface surrounding the LC material deposit, and a maximum height H2,
measured in a direction perpendicular to the underlayer surface surrounding the LC
material deposit, so that L2 is greater than H2, wherein the liquid crystal deposit is
shaped to project above the underiayer surface surrounding the LC material deposit.
In a sixth preferred aspect, the present invention provides a use of a photonic device
according to the third or fifth aspect, in which the photonic device is subjected to
illumination by a source of electromagnetic radiation and provides a corresponding
response which is detected by a detector or by observation.
Any of the aspects of the invention may be combined with each other.
Any of the aspects of the invention may have any one or, to the extent that they are
compatible, any combination of the following optional features.
The term liquid crystal (LC) material as used herein describes a material containing at
least 50 wt.%, preferably at least 75 wt. %, more preferably at least 90 wt.% of at least
one chemical compound that exhibits liquid crystalline behaviour. Optionally the LC
material contains a plurality of chemical compounds known to exhibit liquid crystalline
behaviour. Preferably the LC material contains elongated molecules.
Suitably the LC material is a chiral LC material, that is a material containing at least 50
wt.%, preferably at least 75 wt.%, more preferably at least 90 wt.% of at least one
chemical compound that exhibits liquid crystalline behaviour and a chiral additive, for
example BDH-1281. The addition of a chiral additive allows the chirality of the LC
material to be controlled by controlling the periodicity of the variation in refractive index in
the LC material. Suitable chiral additives are described in US Patent 8217792 and
WO 201 1/137988 Suitably the chiral LC material contains less than 10 wt.% of chriai
additive. Preferably the chiral LC material contains about 2 wt. % to 6 wt. % of chiral
additive. Chiral LC materials have a tendency to align in a helicoidal arrangement.
Chiral LC materials are particularly suitably for the formation of a band-edge laser.
Alternatively the chiral LC material contains a chiral chemical compound known to exhibit
liquid crystalline behaviour.
The LC material may be one, o r more, of nematic, chiral nematic, smectic o r blue phase
materials. Chiral nematic materials are particularly preferred.
Suitably the LC materials form a laser. Preferably the LC material exhibits photonic
band-edge iasing. Alternatively the LC material may exhibit random iasing.
Optionally the LC material includes a fluorescence dye, a fluorescent laser dye, a
quantum dot, o r other light harvester o r gain additives, such as Nd:YAG, Ti:sapphire,
Crsapphire , CnLiSAF Er:YLF, Nd:glass, and Er:glass. to allow the LC material to
function as a Iasing medium.
Suitably the LC material exhibits a nematic phase. A chiral LC material exhibiting a
nematic phase is particularly suitable for the formation of a band-edge laser. However,
these materials may also be used to form a random laser.
Optionally the LC material exhibits a smectic phase. Chiral smectic LC materials are
suitable for the formation of a band-edge laser and may also be used to form a random
laser.
Optionally the LC material exhibits a blue phase i , I o r 1 . Blue phase materials are
particularly suitable for the formation of a band-edge laser.
In alternative embodiments, it is not necessary for the LC material to form a laser. This is
the case where, for example, it is intended that the photonic device is a passive device.
Suitable passive devices include, for example, Bragg-like reflectors, where a known
portion of the electromagnetic spectrum is selectively reflected over other regions of the
spectrum.
Preferably the aliquot of liquid crystal material is provided by Inkjet printing. To overcome
the problem of providing accurate spatial positioning, the present inventors have
developed an inkjet-based process which can preferably be used to construct arrays of
LC lasers or other photonic devices whilst preserving the desirable emission
characteristics.
The method of the present invention may be used to construct patterned arrays of liquid
crystal material deposits, for example a pre-designed complex two dimensional pattern.
The patterned array may also be a regular array of liquid crystal deposits.
The photonic device of the present invention may have a plurality of liquid crystal
deposits in a regular and/or patterned array.
Optionally the liquid crystal deposit is shaped to project above and below the flowable
material layer (or underlayer surface) surrounding the LC material deposit.
Optionally the flowable material layer at least partially encapsulates the LC deposit.
Where, for example, the LC deposit adopts a lenticular shape, the flowable material layer
may encapsulate one of the major convex surfaces of the lenticular shape
The additional advantage of using an Inkjet process is the fiexibiiity in not only depositing
the laser materials themselves, with controllable emission characteristics, but that further
additive processing is made significantly easier. Thus, for example, further materials can
be deposited via Inkjet printing. The flowable material layer may be deposited via inkjef
printing (before deposition of the LC material). Other materials may also be deposited in
this way, such as other polymeric layers to assist with or provide protection of the LC
material and/or improve alignment within the LC material.
The length L 1 of the liquid crystal deposit is the maximum distance across the liquid
crystal deposit on the flowable material layer, measured along a straight line parallel to
the flowable material layer surface. For example, when the liquid crystal deposit is a
substantially circular island when viewed in plan view, L 1 is the diameter of the island.
The liquid crystal deposit has a minimum width W . The width W1 of the liquid crystal
deposit is the minimum distance across the liquid crystal deposit on the flowable material
layer, measured along a straight line parallel to the flowable surface and passing through
the centre point (or centroid) of the liquid crystal deposit when viewed in plan view. Here,
the surface of the flowable material layer is considered before deposit of the LC material
deposit. For example, when the liquid crystal deposit is a substantially circular island
when viewed in plan view, W1 is the diameter of the island.
The width W2 of the liquid crystal deposit is the minimum distance across the liquid
crystal deposit on the support layer (or underlayer), measured parallel to the support
layer surface (or the underlayer surface) surrounding the LC deposit, in a similar manner
to W . W2 may be different to W1 due to a transformation of the flowable material layer
to the support layer (or underlayer).
The length L2 of the liquid crystal deposit is the maximum distance across the liquid
crystal deposit on the support layer (or the underlayer), measured parallel to the support
layer surface (or the underlayer surface) surrounding the LC deposit. For example, when
the liquid crystal deposit is a substantially circular drop, L2 is the diameter of the drop.
L2 may be different to L 1 due to a transformation of the flowable material layer to the
support layer (or underlayer).
The length L 1 can be measured via static image microscopy after deposition of the
deposit. The length L2 can be measured via static image microscopy after the step of
transforming the flowable material layer into the support layer.
The width W1 can be measured via static image microscopy after deposition of the
deposit. The width W2 can be measured via static image microscopy after the step of
transforming the flowable material layer into the support layer.
The diameter D 1 can also be measured via microscopy in the case of Inkjet printing, D 1
can be measured via video microscopy by capturing images of the generated drop after
generation from an inkjet nozzle but before deposition at the flowable material layer.
Alternatively, for other deposition processes, D 1 can be calculated based on knowledge
of the volume V of the aliquot of LC material.
The height H 1 of the LC material deposit is the maximum height of the liquid crystal
deposit measured perpendicular to the flowable material layer surface. Here, the surface
of the flowab!e material layer is again considered before deposit of the LC material
deposit.
The height H2 of the liquid crystal deposit is the maximum height of the LC material
deposit measured perpendicular to the support layer surface (or the underlayer surface)
surrounding the LC material deposit.
The height H 1 and H2 of the liquid crystal deposit can also be measured via static image
microscopy after deposition of the drop. The height H 1 and H2 can also be measured
using SE .
To overcome the problem of poor alignment within the LC material, the present inventors
have developed an approach taking advantage of the fact that certain flowabie materials
can be identified and selected in which the LC materials are not substantially miscible.
For example suitable LC materials tend not to be miscible in polymer solutions such as
aqueous PVA. This is demonstrated in References [9], [1 ] and [12], in which an
emulsion of the LC material phase in a continuous phase of aqueous PVA is formed.
The present inventors have found that when the droplets of the LC phase are smaller in
volume than the flowabie material, e.g. the polymer solution, as in the case of small
deposits on a flowabie material layer, e.g. a wet film, the interfacial tension stresses and
distorts the LC phases (deposits). The effect of this is to promote the desired alignment
of the LC molecules in the liquid crystal deposit.
The present inventors have found that Inkjet printing of a LC material allows for accurate
spatial positioning of the LC material on the surface on which it is printed. Inkjet printing
of a LC material onto a flowabie material that is substantially immiscible with the LC
material improves the spatial positioning of LC material on the surface and also improves
alignment within the LC material. The substantial immiscibilify of the two materials
means that the materials form distinctive phases when placed in contact with one
another. Where the LC material deposit has a circular shape in plan view, the interfacial
tension between the LC material and the flowabie material layer shapes the deposit of
the LC material to have a diameter D2 which is greater than the diameter D 1 of a sphere
with the same volume V as the aliquot of LC material deposited. This distortion induces
alignment of molecules within the LC material. The non-contact and "self-assembly"
nature of this method allows for low-cost and flexible manufacturing of photonic devices
on a broad range of surfaces. This method also allows for precise control of patterning
along with control over the photonic property of the LC material by inducing alignment in
the LC material.
Suitably the volume of flowable material in the flowable material layer is greater than the
volume of LC material deposited by Inkjet printing in the process of the present invention.
Preferably, the depth of the flowable material layer (or underlayer) is greater than the
maximum height H and/or H2 of the LC material deposit. More preferably, the depth of
the flowable material layer (or underlayer) is greater than the diameter D 1 of a sphere
with the same volume V as the aliquot of LC material.
Preferably H2 is greater than mhi , preferably greater than 5 m i. Preferably H2 is less
than 00 m h . Preferably H2 is in the range 1 to 100 miti , more preferably 5 m i to
50 ΐ and most preferably in the range 5 m t to 30 miti .
Preferably the ratio of H 1 to H2 is not less than 1:1.
Preferably the ratio of H 1 to H2 is not more than 50:1 .
A deposit of LC material having H2 within the values described above is considered to be
particularly suitable for use as a laser due to the resultant length of lasing cavity.
Preferably the ratio D 1 to H 1 is less than 50:1 .
Preferably the ratio of L2 to H2 is from 2:1 to 200:1 .
Preferably, the ratio of L 1 to D 1 is not more than 20:1, preferably less than 10:1 , and
most preferably less than 3:1.
Preferably, the ratio of L 1 to H 1 is not less than 1:1 .
Preferably, the ratio of L 1 to H 1 is not more than 50:1.
Preferably, the ratio of L2 to H2 is not less than 1.1 :1
Preferably, the raiio of L2 o H2 is not more than 1000:1 .
Preferably the ratio of W1 to D 1 is not less than 0.1:1 .
Preferably the ratio of W1 to D 1 is not more than 20:1
Preferably the ratio of W1 to W2 is not more than 1:1 .
Preferably the ratio of W1 to W2 is not less than 0.01:1 .
Preferably the ratio of L 1 to W1 is not less than 1:1.
Preferably the ratio of L 1 to W1 is not more than 200:1 .
Preferably the ratio of L2 to W2 is not less than 1:1.
Preferably the ratio of L2 to W2 is not more than 1000: 1.
The present inventors have found that operating within the ranges identified above tends
to promote alignment of the LC material in the LC material deposit, due to shaping
effects caused by interaction with the flowable material layer.
In some embodiments, LC materials are deposited by Inkjet printing onto a liquid layer.
The liquid layer here is an example of the flowable material layer of the second aspect of
the invention.
In some embodiments, the liquid layer is deposited by film coating using a doctor blade,
or bar coating, or roll-coating or Inkjet deposition of either a continuous wet film (e.g.
solution layer), individual drops, groups of connected drops, or multiple drops in the
same location.
Suitably the method comprises a step of transforming the flowable material layer into a
support layer. Typically, this takes place after deposition of the LC material drop.
Optionally the step of transforming the flowable material layer includes curing the
flowable material layer to form a support layer. The step of transforming the flowable
material layer into a support layer may involve any chemical or physical process which
may convert, e.g. a liquid, into a solid or a semi-solid. Optionally the step of transforming
the fiowabie material layer involves cooling (e.g. solidification), solvent evaporation,
cross-linking, or polymerization (such as photo induced polymerization) of the fiowabie
material layer. When the fiowabie material is a solution, transformation into the support
layer may involve evaporation of some or all of the solvent from the solution. The
transformation of the fiowabie material layer into a support layer provides the advantage
that the LC material can be supported at a desired location within the support layer.
Therefore, the support layer preferably prevents movement of the LC material drop from
the desired location, e.g. during movement or vibration of the photonic device.
The step of transforming the fiowabie material layer into a support layer may also involve
shrinking the fiowabie material layer. For example, when the fiowabie material is a
solution, evaporation of the solvent to form the support layer may also result in shrinking
of the fiowabie material layer. Shrinking of the fiowabie material may further distort the
drop of the LC material to further improve alignment of molecules within the LC material.
The step of transforming the flovv'able material layer into a support layer may also involve
distorting the LC material deposit. The maximum length of the LC material deposit after
the step of transforming the fiowabie material layer into the support layer is L2. The
maximum height of the LC material deposit after the step of transforming the fiowabie
material layer into the support layer is H2.
In some embodiments the maximum length of the LC material deposit increases during
the transformation of the fiowabie material layer into the support layer such that L2 is
greater than L1. This further improves alignment within the LC material.
In some embodiments the maximum height of the LC material deposit decreases during
the transformation of the fiowabie material layer into the support layer such that H2 is
less than H1. This further improves alignment within the LC material.
Optionally, after the transformation of the fiowabie material layer into a support layer, the
ratio of the maximum length L2 of the LC material deposit on the support layer to the
diameter D 1 of the sphere having the same volume V as the aliquot of LC material is
preferably less than 20:1 , more preferably less than 10:1 , and most preferably less than
3:1
Suitably the method comprises the step of curing the LC material deposit. The step of
curing the LC material may include photopoiymerization of reactive monomers, for
example when liquid crystalline mono- and di-acrylate materials are contained in the LC
material or where the LC material itself is polymerizable. Curing the deposited drop of
LC material prevents disruption of the improved alignment achieved by the method of the
present invention, e.g. during movement or vibration of the photonic device.
Suitably the fiowabie material is a liquid. Preferably the liquid is a solution, for example a
polymer solution. The liquid may be a colloidal solution, suspension or emulsion in
some embodiments the fiowabie material layer is a polymer-dispersed liquid crystal layer
as described in References [ 1 ] and [12]. In other embodiments, the fiowabie material
may be a material which deforms plastically in response to the arrival of the generated
drop, e.g. a gel or a paste.
When the fiowabie material is a polymer solution, the polymer solution may comprise a
polymer selected from the group including: PVA; poiyurethane; polyamides, e.g. Nylon
6,6; P A; poiyimides, poly(pyromei!itic dianhydride oxydianilines) and polystyrene.
The solvent may be any suitable solvent, for example: water, dichioromethane, formic
acid, acetone, iso-propyl alcohol, toluene, cyclohexane or other organic solvents or
derivatives, for example.
Optionally the polymer solution has a concentration from 1 wt % to 30 wt %. More
preferably the polymer solution has a concentration from 5 w % to 20 wt %.
In some embodiments the fiowabie material comprises a lasing material, for example the
fiowabie material may be an emulsion based lasing medium as described in References
[ 1 ] and [12]. When the LC material deposit comprises a lasing material, the fiowabie
material may exhibit the same lasing action as the LC material deposit. Alternatively the
fiowabie material may exhibit lasing action of a different type to the LC material deposit.
Preferably the fiowabie material contains an alignment component to promote alignment
in the LC material. The alignment component may include poiyimides, surfactants,
polymers (e.g. polyvinyl alcohol, polyurethane, polyamides, Nylon 8,8, polymethyl
methaery!ate or po!y(pyromellitic, polydiandydride oxydianiline)) or derivatives of these
materials which promote a preferred orientation of the LC.
The flowable material containing an alignment component provides the advantage of
providing chemical control of alignment within the LC material in addition to the physical
control by shaping the LC material deposit. Therefore the use of an alignment
component further improves alignment within the LC material.
Preferably the flowable material contains an alignment component to promote planar
degenerate alignment in the LC material. When the LC material is a chiral LC material,
suitably the planar degenerate alignment component causes homeotropic alignment
(perpendicular anchoring) of the LC optical axes within the LC material deposit.
The use of a planar degenerate alignment component also further improves alignment
within the LC material. For example, a chiral LC material contains molecules which selforganise
along a heiicoidal axis, as discussed above. The shaping of the LC material
deposit described above improves the alignment of the heiicoidal axes. Providing a
planar degenerate alignment component in the flowable material layer causes molecules
at the base of the LC material deposit to align parallel to the surface of the flowable
material layer. This alignment of molecules at the base of the heiicoidal structures
causes the heiicoidal axes to align perpendicular to the flowable material layer surface
(or underlayer surface). This is particularly advantageous for band-edge iasing.
Suitably, the flowable material layer is formed on a substrate. Another advantage of the
present invention is that the choice of substrate is not particularly limited. The substrate
may be any material onto whose surface the flowable material may be deposited and
which provides a suitable support for the photonic device. The substrate may be lighttransmissive
or reflective, e.g. to allow illumination of the LC material drop with pumping
radiation for operation as a laser. Therefore suitable substrates include iighttransmissive
glass and iight-transmissive plastics. The substrate may, for example, be
rigid or substantially rigid. Alternatively, the substrate may be flexible.
The surface of the substrate may be patterned with structures, such as wells or barriers.
The patterned substrate allows further control of the spatial location, or shape of the
flowable layer, deposited LC material and/or protective layers.
Preferably the flowable material layer is deposited by film coating using a doctor blade,
bar coating, roll-coating or Inkjet deposition of a continuous film, individual drops, or
groups of connected drops. Inkjet deposition of the flowable material allows continuous
"printing" of LC photonic devices.
Alternatively, the flowable material may be deposited in discrete regions, for example, in
the form of either individual deposits or groups of connected deposits to form lines or
other features. The provision of discrete regions of flowable material layer allows
asymmetric stress to be induced in the later deposited LC materials to produce desired
optical features.
When inkjef printing is used to deposit the flowable material, the digital nature of the
Inkjet deposition method also allows flexibility of altering the order and location of
material deposition, e.g. LC materials onto flowable material or vice versa, or creating
multi-layer structures consisting of one or more layers of LC materials and other flowable
materials. The application of the method of the present invention described can also
extend to a wider range of LC materials, including but not limited to nematic, chiral
nematic, smectic, blue phase or any combination of these materials.
Suitably, the method comprises a step of providing a protective layer. Preferably, the
protective material layer is deposited on top of the LC material deposit. The protective
material may be the same material as the flowable material. The protective material
layer may be transformed into a protective support layer. Preferably the protective
material layer and the flowable material layer (or support layer, or underiayer) together
totally encapsulate the LC material deposit. The protective material layer may also
further shape the LC material deposit to induce further alignment within the LC material.
The protective material layer may provide a hydrophobic or hydrophiiic surface. The
protective material layer may be an oxygen scavenger or getter. The protective material
layer may be a moisture barrier or a preferential absorber. For example, polyurethane,
PVA, poiydimethylsiloxane or other silicones may be used. The optional and preferred
features described above for the fiowable material layer also apply to the protective
material layer. For example, preferably the protective layer contains an alignment
component to improve alignment in the LC material deposit. Suitably protective
materials may comprise: PVA , polyurethane, Nylon 6,8, po!ymethyl methacrylate,
poiyimides, poly(pyromei!itic dianhydride oxydianiline), metal-oxide polymer composites
or derivatives of these materials.
As mentioned above, preferably the fiowable material layer has a thickness T 1 greater
than diameter D 1 that would be attributed to the volume V of the LC material aliquot.
This allows the fiowable material layer to shape the deposit of LC material .
Preferably the fiowable material has a thickness T 1 less than 10 times the diameter D1 of
the generated drop of LC material. Suitably the thickness T 1 is between 10 mm and 10
nm, more suitably between 1 mm and 1 m h, and more suitably still between 100 m n and
10 . if T 1 is too large the drop of LC material deposited on the fiowable material layer
may be moved from the location of deposition by currents caused within the fiowable
material. For example, when the fiowable material is a solution, the length of time the
fiowable material exists in a liquid phase is typically increased as the thickness of the
fiowable material layer is increased. As the solvent evaporates from the solution layer
this may cause a current to flow in the fiowable material which may disturb the position of
a drop of LC material on the fiowable material layer. Therefore control of the thickness of
the fiowable material layer is advantageous. Control of the curing rate of the fiowable
material layer is also advantageous for the same reasons.
Preferably the ratio of the thickness T2 of the support layer to the thickness of the
fiowable layer is in the range 1:1 to 0.01 :1.
Preferably the fiowable material layer has a substantially constant thickness across the
layer. nkjet printing of the fiowable material layer allows precise control of the thickness
of this layer.
Suitably the protective layer has a thickness in the range of 0nm to 10mm.
Preferably the method comprises providing a second, and optionally a third, and
optionally a fourth etc. , aliquot of a LC material and depositing it on a fiowable material
layer, i.e. steps (i) and (ii) are repeated in this way, there can be provided a device
having a plurality of photonic locations such as active photonic locations. Suitably the
second and optionally further deposits of LC material are deposited on the same flowable
material layer as the first drop but each in a different location from the first drop in this
way the method may be used to obtain an array (preferably an ordered array) of LC
material deposits on the flowable material layer. Alternatively the second, and optionally
third, and optionally fourth etc., deposits may each be deposited on a different flowable
material layer, i.e. a second, and optionally third, and optionally fourth etc., flowable
material layer. In this way the method may be used to obtain LC material deposits on
several separate flowable material layers. In this case, the flowable material layers may
be different, e.g. in terms of composition, thickness etc. in order to provide different
control to the drops of LC material.
In some embodiments the method comprises generating a second, and optionally a third,
and optionally and fourth etc., aliquot of a LC material and depositing the LC material on
a flowable material layer in the same location as the first LC material deposit. This
allows the size of the LC material deposits to be controlled.
In some embodiments, when a plurality of aiiquots of LC material are provided, the LC
material deposited in different locations may be the same LC material. Alternatively the
LC material deposited in different locations may be different LC materials, for example
when different lasing action is required at different locations.
Preferably the ratio of the volume V (measured in m 3) of the aliquot of LC material to the
length L 1 (measured in miti ) of the LC material deposit is in the range 10:1 to 1,000,000:1
m i2.
In some embodiments, it is preferred that the flowable material layer comprises two or
more distinct layers. This can be advantageous in order to provide an upper layer that
provides a specific desired interaction with the incoming LC aliquot and a lower layer (or
lower layers) that provides either a desired interaction with the incoming LC aliquot or
another a desired interaction with the upper layer.
In a sixth preferred aspect, the present invention provides a use of a photonic device
according to the third or fifth aspect, in which the photonic device is subjected to
illumination by a source of electromagnetic radiation and provides a corresponding
response which is detected by a detector or by observation.
n relation to the sixth aspect of the invention, there are several modes of operation of the
photonic device which are contemplated. These depend on the device itself and on the
illumination of the device.
Where the photonic device is a laser, the device typically incorporates a laser dye. The
illumination by a source of electromagnetic radiation preferably provides optical pumping.
In this case the source is itself typically a laser. However, the source may alternatively
be an LED such as a high power LED.
It is possible to operate the laser above threshold. That is, the optical pumping provided
by the source is sufficient to provide lasing in the LC material deposit.
However, it is alternatively possible to operate the laser below threshold, by suitable
adjustment of the power of the source, the output spectrum of the source, or by using a
different source. In this case, the laser dye may still fluoresce, but the number of
photons emitted by the laser dye is insufficient to cause true lasing. However, the optical
output of the device may include characteristics related to the interaction of the photons
emitted by the laser dye and the photonic band gap of the LC material deposit n this
case, therefore, below-threshoid operation of the photonic device may be suitable to
provide a characteristic output that can be detected or observed. In this manner, belowthreshold
operation of the photonic device may provide a security feature that can be
interrogated using a suitable illumination source. Furthermore, other fluorescent
chromophores may be used in place of a conventional laser dye. These may include
other fluorescent taggants, dyes or quantum dots, for example, where the native
fluorescence is modified by the presence of the liquid crystal photonic bandgap.
It is of particular interest to note that the same photonic device can be subjected to either
of the modes of operation mentioned above. Thus, where a suitable source of
electromagnetic radiation is available, the photonic device can be operated above
threshold, with the resultant and the laser output from the device. However, where only a
lower power source of electromagnetic radiation is available, the photonic device can be
operated below threshold, with the resultant below-threshoid characteristic output.
The photonic device need not incorporate a laser or fluorescent dye. The photonic
device may be used in passive mode n this case illumination of the device by ambient
light or by light from a particular source (e.g. an LED of known spectral output) can cause
selective reflection from the photonic device based on the photonic bandgap. Nonfluorescent
dyes, or material which absorbs certain portions of the electromagnetic
spectrum, may also be added to the mixture to create a characteristic signature.
In each of these modes of operation, it is preferred that multiple photonic devices are
provided, arranged in a suitable array or pattern. The array or pattern may be ordered,
e.g. it may have some degree of symmetry or provide a recognisable shape. However, it
is not essential that the array or pattern is ordered. A truly random or an apparently
random array or pattern can be used. The positional location of the devices on the
substrate and relative to each other can be used to encode information. Such arrays or
patterns are straightforward to achieve based on the Inkjet printing approach described.
The optical response may vary from device to device in the array. The resultant arrayed
optical response of the photonic devices, when suitably illuminated, provides a powerful
basis for a security feature for identifying objects or documents of value.
Further optional features of the invention are set out below.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example with reference to
the accompanying drawings in which:
Fig. 1 shows the emission spectrum under optical excitation at a wavelength of 532nm
for a deposit of comparative example 1;
Fig. 2 is a schematic view showing the creation of the fiowabie material layer according
to an embodiment of the present invention;
Fig. 3a is a schematic view showing Inkjet printing of a LC material according to an
embodiment of the present invention;
Fig 3b is an enlarged view captured during microscopic imaging of he print head shown
in Fig 3a at 0 m during generation of a deposit of LC material;
Fig. 3c is an enlarged view captured during microscopic imaging of the print head shown
in Fig. 3a at 20 m during generation of a deposit of LC material;
Fig. 3d is an enlarged view captured during microscopic imaging of the print head shown
in Fig. 3a at 50 m during generation of a deposit of LC material;
Fig 3e is an enlarged view captured during microscopic imaging of the print head shown
in Fig. 3a at 250 s during generation of a deposit of LC material;
Fig. 4a is a scaled high-speed microscopic image showing the deposit of LC material
generated by an Inkjet printing head at a reference time of 0 ms;
Fig. 4b is a scaled high-speed microscopic image showing the deposit of LC material
impacting the surface of the flowable material layer 0.2 ms after the reference time;
Fig. 4c is a scaled high-speed microscopic image showing the deposit of LC material on
the flowable material layer 0.6 ms after the reference time;
Fig. 4d is a scaled high-speed microscopic image showing the deposit of LC material on
the flowable material layer 100 ms after the reference time;
Fig. 4e is a scaled high-speed microscopic image showing the deposit of LC material on
the flowable material layer 500 ms after the reference time;
Fig. 4f is a scaled high-speed microscopic image showing the deposit of LC material on
the flowable material layer 2 s after the reference time;
Fig. 5a is a schematic cross-section showing the deposit of LC material on the flowable
material layer;
Fig 5b is a schematic plan view showing the deposit of LC material on the flowable
material layer;
Fig 6 is a graph showing the laser emission following optical excitation at the absorption
maximum of the laser dye from a deposit of LC material deposited according to the
present invention; and
Fig. 7 is a graph showing output intensity as a function of excitation energy for the same
LC material as Fig. 8 .
Fig. 8 is a graph showing an example reflection band for a chiral nematic LC material and
for the same chiral nematic LC materia! combined with a dye.
Fig. 9 shows the spectral response for the sample of Example 5 .
Fig. 0 shows the spectral response for the sample of Example 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS. AND FURTHER
OPTIONAL FEATURES OF THE INVENTION
Chiral nematic liquid crystals (LCs) are a unique class of functional photonic materials
with applications ranging from bistable displays to lasers. 1 1 In these materials, the
constituent elongated molecules self-organize into a helicoidai arrangement around the
helical, or optical, axis. The resultant periodic variation of the refractive index gives rise to
a photonic band-gap for visible wavelengths. This has recently received significant
interest in the context of photonic band-edge lasing, i , since incorporation of an organic
fluorescent dye, as the gain medium, into the helical structure, or optical cavity, can lead
to laser emission at the photonic band-edges. Such systems offer high slope efficiency,
greater than 60%, narrow linewidth emission i and, with the self-organized "soft"
periodic structure, broadband wavelength selectivity and tuneability. Typical laser
emission wavelengths are in the range 450 n to 850nm i . The present invention
exploits the liquid-like properties of the chiral LC laser and describes an Inkjet deposition
approach for these materials. Such an approach allows simple and arbitrary positional
control of laser sources, incompatible with conventional laser processing and fabrication,
to realize new classes of functional photonic materials and devices.
Lasing LC media offers significant potential for not only reducing manufacturing cost, but
also to form coatings on surfaces, or devices, currently inaccessible to the traditional
processing required in the fabrication of semiconductor lasers. Precise and controllable
positioning of the location and size of individual laser deposits would significantly improve
the functionality of the laser coatings and devices. Ordered laser array structures, for
example, would be of particular interest in bio-assay arrays, optofluidic applications and
new information displays.
In recent years, there has been increased interest in using direct writing processes such
as inkjet printing as flexible fabrication methods for electronics and biological devices
The present invention uses a "drop-on-demand" S inkjet deposition process that controls
precisely the aliquot size and allows the formation of spatially localized arrays of LC
material deposits, for example spatially localized laser sources. By depositing the LC
lasing material onto a flowable material, e.g. a wet, solution-based polymer, the
necessary alignment within the LC material can be obtained.
When the LC material contains a laser dye, following optical excitation at the absorption
maximum of the laser dye, single-mode laser emission is observed with a well defined
threshold and narrow linewidth when the necessary alignment within the LC material is
obtained. The present invention shows that the Inkjet deposition process has only a
minor effect on the lasing threshold and emission characteristics of the LC laser system
relative to control cells fabricated using conventional glass cell assembly methods. The
results demonstrate the possibility of creating truly two-dimensional laser arrays of
controlled and arbitrary size, position, and wavelength for use in a diverse range of
applications.
Although a central aim of the development of the present invention has been to
manufacture laser devices, it is not essential that the final device is a laser device. Other
photonic devices are contemplated. Other optical effects can be generated, enabled by
the alignment of chirai nematic liquid crystals.
The inherent chirai nematic liquid crystal optical photonic bandgap, also known as the
selective wavelength reflection band, can also be used by itself to create optical effects
and photonic devices, e.g. without the need to add a laser dye, or even with the addition
of a laser dye but without above-threshold operation of the laser dye.
One of the key properties of aligned chiral nematic liquid crystals is this well-defined onedimensional
photonic band-gap for light propagation parallel to the helical axis. In order
to observe the photonic band-gap effect, the intrinsic pitch of the chiral nematic liquid
crystal (i.e. the distance for 360° rotation of the local nematic director or preferred
orientation) should be of the same order as the wavelength range of interest. This optical
property of chiral nematic liquid crystals is well known in the literature (see, for example,
H.J. Coles, "Handbook of Liquid Crystals" Vol. 2A (Chapter 4} "Chiral nematics: Physical
properties and applications" pages 335-41 1, Editors D. Demus, J . Goodby, G.W. Gray,
H.-W. Spiess, V. Vi , Wiley (1998)).
An example reflection band shown in Fig. 8 . in this case, 3.9% w/w of the high-twisting
power chiral additive BDH-1281 was added to the liquid crystal host BL006. The mixture
was capillary filled into a test cell comprising glass substrates, separated by 9 m spacer
beads and where the surfaces were treated (rubbed po!yimide) to obtain helical
alignment perpendicular to the substrates. The ceil was then mounted on a microscope
(Olympus BX-51), illuminated with white light, and the characteristics of the transmitted
light measured by spectrometer (Ocean Optics USB2000).
The position of the central wavelength of the photonic band-gap, c , and width of the
reflection band, Al , is determined by the intrinsic pitch, P (the length scale at which the
LC director rotates by 380°) of the liquid crystal and the birefringence, An, of the nematic
liquid crystal host, given by the following relations:
c = na vP and Al = nP
where n av is the average of the refractive indices parallel and perpendicular to the local
nematic director. Through choice of the pitch (readily manipulated through concentration
of the chiral additive) and/or birefringence, the position and width of the reflection band
can be easily adjusted.
The 1-D photonic band-gap only exists for light propagating parallel to the helical axis.
Therefore, to observe the photonic band-gap for chiral nematic liquid crystals where the
viewing direction is substantially perpendicular to the substrate, the chiral axis should be
aligned substantially perpendicular to the substrate also. The preferred embodiments of
the invention, described below, promote such alignment through a print deposition
process. In some embodiments, it may be useful to have certain values of the pitch
and/or birefringence such that certain wavelengths, or ranges of wavelengths, are
preferentially reflected. For example, for certain effects it may be advantageous to have
different regions reflecting red, green, or blue portions of the spectrum, or regions outside
of the visible spectrum. Preferably, the reflection band may be intentionally designed to
reflect a known portion of the spectrum created by a device equipped with an LED light
source (e.g. mobile phone, camera phone, smart phone) where otherwise the material
possesses only low visibility to the unaided eye. In principle, any portion or part of the
optical spectrum may be selectively reflected.
It may also be practically useful to add absorbing dyes to the liquid crystal host in order
to further modify the absorption characteristics. Also shown in Fig. 8 is a sample in
which 1% PM-597 dye was added to the host chiral nematic liquid crystal. The optical
characteristics measured are essentially a superposition of the dye absorption and liquid
crystal reflection band. Many choices of dye would be obvious to those skilled in the art;
in particular for authentication and security applications if may be beneficial to add dyes
which absorb outside of the visible spectrum, for example.
The optical effects described are particularly applicable in creating unique optical
signatures for anti-counterfeiting, brand authentication and general security printing and
packaging, for example.
In addition to the passive optical reflection described above, other practically useful
photonic effects may be generated. These include pre-threshold laser emission or
fluorescence modified by the presence of the chiral nematic photonic band-gap, for
example. Further details are provided in Examples 5 and 8 , below.
The liquid crystal (LC) material used in the following examples was prepared by adding
4.2 wt% of the chiral additive BDH1281 (Merck KGaA) to the achirai nematic LC BL006
(Merck KGaA) to generate the chiral nematic phase(BL006 is a commercially available,
wide temperature nematic liquid crystal mixture comprising 4-cyano -4'-pentyl - 1,1'-
biphenyl and terphenyi derivatives). The high quantum efficiency laser dye,
Pyrromethene-597 (1,3,5,7,8-pentamethyl-2,6-di-t-butylpyrromethene-difluoroborate
complex, obtained from Exciton, and used without further purification), was added to the
chira! nematic mixture at a concentration of 1 % w/w. Mixtures were placed in an oven
for a period of 24 hours at 10 °C above the nematic to isotropic transition temperature to
ensure sufficient thermal diffusion of the constituents. n order to confirm the position of
the long-wavelength photonic band-edge, which defines the laser wavelength of the LC
deposit, mixtures were capillary filled into 10 thickness glass cells, which had
antiparallei rubbed polyimide alignment layers.
Initial experiments were performed depositing the lasing LC formulations onto cleaned,
plain glass substrates. The optimized lasing LC mixture contained the nematic liquid
crystal BL006, high twisting power chiral additive (4.2% wt BDH-1281) and fluorescent
dye (1% wt pyrromethene-597). The mixture was designed to have an emission
wavelength at the gain maximum of the dye, close to 585 nm in LC media. The viscosity
of the LC mixture was around 10 mPa.s at 20°C, significantly greater than the jetting
limit of 20 mPa.s, suggested by the print head manufacturer (MicroFab). However,
extended rheological measurement of the LC mixture has shown that its viscosity
decreases significantly at elevated temperature, obeying the typical Arrhenius behaviour.
While commercial Inkjet systems typically process inks at room or modestly elevated
temperature, much higher ink temperature has been shown to be feasible for printing
functional materials such as phase-change resists. Therefore, the print head was
heated to 90°C to 95°C, close to the isotropic to nematic transition point of the LC laser
mixture, to provide the optimum viscosity for printing. After printing, uniform sessile
drops were obtained with a typical diameter of approximately 200 microns.
A deposit obtained after inkjet deposition onto the cleaned, plain glass substrate was
examined between crossed polarizers. It was dear that disciination lines, representing
defects in the director orientation, were widespread across the droplet. Non-uniformity
was also visible within the deposit, in this case a substantially circular drop, indicated by
a change in colour from the center of the drop to the edges. The colour of the drop,
when viewed under cross polarizers was red at the centre with the colour changing to
blue towards the edge of the drop as the drop thickness reduces.
To examine the emission characteristics, samples were optically excited by the second
harmonic of an Nd:YAG laser (532 nm, 3-4 ns pulse duration), focused to a spot size of
110 microns. The resultant emission profile, shown in Fig. 1, demonstrates a strong
multi-mode lasing output, characterized by a series of variable linewidth peaks between
approximately 560 n and 620 nm (corresponding to the fluorescence emission curve of
PM-597). The large number of lasing modes is indicative of multiple domains within the
droplet, consisting of regions with different values of the helical pitch.
Previous work, in rubbed planar surface aligned LC ceils, described by Morris et a ,
[2005] ,¾ showed that multi-domain samples with slightly different pitch values, and with a
typical domain size equal to or less than the pump spot size, resulted in multi-mode
lasing output. On the other hand, monodomain samples exhibited high quality, single
mode lasing. Poor emission characteristics, such as those presented in Fig. 1,
significantly limit the scope of laser applications, which typically demand narrow
iinewidths centered on a well-defined emission wavelength.
Example 1
10 wt. % polyvinyl alcohol PVA (average molecular weight 10,000 amu, 85% hydroiysed)
solutions were drop-casted onto clean glass slides to form wet PVA films. 50 pm-thick
poiyimide (Kapton) tapes were laid down on the glass slide first as depth gauges before
the PVA solution was deposited using a second glass slide as a squeegee. A custom
printing rig, consisting of a single-nozzle Microfab printing device (80 nozzle
diameter) was used to pattern the LC deposits onto the wet PVA film. To reduce the
viscosity of the LC mixture from 110 mPa.s at room temperature to the jettable limit of 20
mPa.s of the MicroFab device, the print head was heated and maintained at between
90°C and 95°C, just below the isotropic to nematic transition temperature. A custom
pneumatic/vacuum controller was used to maintain the LC meniscus position at the
nozzle and a bipolar waveform was applied to eject LC material onto the wet PVA film.
In an attempt to combine the desirable features of inducing alignment within the LC
material, for example the alignment necessary to obtain single-mode laser emission
characteristics, with accurate spatial positioning of the LC material, the present inventors
have developed the alternative deposition approach described above in which the LC
material is directly printed mixture onto a fiowabie material layer, for example a wet film
of 0 wt% PVA polymer solution in deionized water, as illustrated in Figs 2 and 3 .
Fig. 2 shows a schematic diagram illustrating the deposition of the fiowabie material 202,
in this case the PVA polymer solution described above, on a substrate 200, in this case a
glass slide. The substrate is provided with a depth gauge 204, in this example Kapton
tape is provided as the depth guage along opposite sides of the glass slide 200. The
fiowabie material 202, e.g. the PVA polymer solution described above, is deposited on
the substrate by any suitable method, for example by drop-casting as described above.
A bar or blade 208, for example a glass slide, is then drawn across the substrate in the
direction shown by arrow 2 0 to leave behind a fiowabie material layer 208 with constant
thickness. The thickness of the fiowabie material layer (the wet film) is defined by the
depth gauge 204 and in this case was approximately 50 nh across the fiowabie material
layer. This method of depositing the fiowabie material layer is a method known as
doctor blading.
Fig. 3a shows a schematic diagram illustrating Inkjet printing of a LC material on a
fiowabie material layer deposited as described in Fig. 2 . The features that were
described for Fig. 2 are not described again but are given similar reference numbers.
Fig. 3a shows a print-head 300 which generates aliquots, in this example drops, of a LC
material and deposits LC material on a fiowabie material layer 208. The print head is
controlled by any suitable control means, for example piezoelectric control means, to
accurately position a LC material deposit on the fiowabie layer. In this example, the print
head Inkjet prints an ordered array of LC material deposits. Figs 3b to 3e show an
enlarged cross-section through the print head tip 302 of print head 300 as a deposit of
LC material is generated and deposited as LC material deposit 304 on the fiowabie
material layer. Fig. 3b shows the print head tip before generation of a drop of LC
material (at 0 m ) . Fig. 3c shows the print head tip at 20 m after generation of the drop
of LC material begins. Fig. 3d shows the print head tip at 50 after generation of the
drop of LC material begins. Fig. 3e shows formation of the drop of LC material 250 s
after generation of the drop of LC material begins; this drop is then deposited onto the
fiowabie material layer 208.
The key stages of a typical droplet deposition event are shown in Figs. 4a to 4f, which
show images captured from a high-speed camera. Fig. 4a shows an approximately
spherical drop of LC material 400 approaching the fiowabie material layer 402 after
generation of the drop by Inkjet printing. Fig. 4b shows the LC droplet impacting the
surface of the fiowabie material layer 402 at 0.2 s after the image shown in Fig. 4a. As
the LC material drop impacts the surface the subsequent deformation of the surface of
the fiowabie material layer and the droplet is evident. However, in Figs. 4c to 4e, frames
at 0.8 ms, 00ms and 500 s respectively after the image shown in Fig 4a, it is clear
that the surface tension and immiscibility of the wet PVA solution to the LC droplet is
sufficient to prevent the droplet entering the bulk polymer solution. Finally, in Fig. 4f, the
2 s frame, the droplet is shown in the equilibrium position on the surface of the film with a
well-defined and symmetrical profile.
The necessary alignment of the LC, in the standing helix configuration, for lasing appears
to be achieved through a combination of interaction of the PVA polymer with the LC and
mechanical forces occurring through deformation of the LC droplet. The interaction of
PVA polymer with both nematic and chiral LCs has been examined previously in the
context of polymer dispersed liquid crystal devices (PDLCs). 1 it was determined that
PVA promotes parallel arrangement of the LC director at the interface, 8, Following
the impact process depicted in Figs 4b to 4e, and the resultant lateral shear as it reaches
an equilibrium state, shown in Fig. 4f, the LC droplet adopts an oblate shape with the
minor-axis perpendicular to the PVA film. The boundary between the LC material and
the flowable material on the surface of the drop of LC material encapsulated by the
flowable material is shown by the dotted line 404. The ratio of the length L 1 of the LC
material deposit (in this example the deposit was a substantially circular drop, therefore
the length L 1 is the diameter of the deposited drop) on the flowable material layer in Fig.
4f to the diameter D 1 of the sphere with the same volume V as the aliquot of LC material
generated (in this example the aliquot of LC material was a substantially spherical drop
of diameter D1) in Fig 4a is approximately 2:1 (D1 was measured to be 80 m h , L 1 was
measured to be 160 m and H 1 was measured to be 5 1 miti ) . When the flowable
material layer and LC material deposit were dried the ratio of the length L2 to D 1 was
approximately 3:1 (L2 was measured to be 250 mhi and H2 was estimated to be 10 ).
It is noteworthy that the droplet does not continue to wet the surface and both the droplet
shape and profile remain fixed after the film has dried. The combination of the parallel
anchoring and lateral motion leads to the standing helix alignment depicted in Fig. 5 and
confirmed through polarizing microscopy.
Fig. 5a shows a schematic cross sectional view of substrate 500 which supports a
flowable material layer 502 with thickness T 1 on which a substantially circular deposit of
LC material 504 is formed. Fig. 5 shows the oblate shape of the deposit of LC material
formed according to the method of the present invention. The deposit of LC material has
a height H 1 and a maximum length L 1 (diameter in this case). In this example, the LC
material is a chiral LC material which contains elongate molecules 506. The immiscibiiity
and the interfacial tension between the LC material and the flowable material induce
heiicoidal alignment in the elongate molecules.
Fig. 5b shows a schematic plan view of a flowable material layer 502 on which a LC
material deposit 504 is formed. The LC material deposit shown in Fig. 5b has an
elliptical shape with a maximum length L 1 and a minimum width W1.
The array of LC material deposits of the present invention, produced as described above
for Example 1, were examined between crossed polarizers. Compared to the deposited
drop onto the untreated surface described above in Comparative Example 1, the LC
material deposits produced according to the present invention possess greater uniformity
than the LC material deposit on a clean glass substrate as described in Comparative
Example 1. All of the LC material deposits deposited according to the present invention
were red in colour across the whole deposit when viewed between crossed polarizers.
This is directly attributable to a more uniform chiral nematic pitch across the deposit
compared to the result described for Comparative Example 1. The texture of the
deposits produced according to the present invention was found to remain invariant
under rotation by 45°, when viewed between crossed polarisers, indicating that the LC
profile is rotationally symmetric within the droplet itself. Furthermore, there is no optical
extinction within the droplet, i.e. there exist no regions in which the LC director is parallel
or perpendicular to the polarizer or analyzer. Combined with the fact that the material is
chiral, wherein the locally uniform liquid crystal director precesses to form a macroscopic
helix, these observations suggest that the likely LC director profile is one in which the
helical axis is perpendicular to the substrate (Grandjean texture or Uniformly Standing
Helix). Such an orientation is a pre-requisite for single-mode photonic band-edge lasing
in chiral LCs normal to the substrate, where the laser emission occurs along the helical
axis. 2
Following the observation of the required chiral LC alignment, the emission
characteristics of the LC lasing deposits were examined.
To measure the excitation laser threshold and the polarization of the emission from the
pyrromethene-doped LC emulsion samples, coated films were photo-pumped by the
second harmonic (wavelength = 532 nm) of an neodymium yttrium aluminium garnet
(Nd:YAG) laser (Polaris II, New Wave Research), which had a 3-4 ns pulse duration and
a repetition rate of 1 Hz. The input energy was modulated by a built-in attenuation
system and monitored using a pyroeiectric head connected to a calibrated energy meter.
n both cases, so as to ensure that the pump beam did not interact with the photonic
band gap, the linear polarization was converted to circular polarization of the opposite
handedness to the helix of the chiral nematie LC using a quarter-wave plate. The pump
beam was then focussed to a spot size of 110 at the sample using a bi-convex lens.
The output from the LC samples was collected in the forward direction of the substrates
(parallel to the axis of the helix) and focussed onto an HR2000 universal serial bus (USB)
spectrometer (Ocean Optics, resolution 0.3 nm) using a lens combination consisting of a
doublet and meniscus lens. To avoid detection of the pump beam, long pass filters were
inserted before the detector to remove the output from the Nd:YAG laser.
After optical excitation at 532nm, the resulting emission spectrum and input-output
characteristics are presented in Figs. 6 and 7 . In Fig 6 , the sample shows clear singlemode
behavior with an emission peak of 580 nm, corresponding to the long-wavelength
of the photonic band-edge and a linewidth of less than 1 nm. Fig. 7 shows a plot of the
input as a function of the output energy, the sample exhibits a lasing threshold of
approximately 300 nJ/puise. For conventional (non-jetted) samples, filled by capillary
action into 10 m n transmissive test cells prepared with anti-parallel alignment layers, the
threshold was measured to be 100 nJ/puise. The main reason for the increased
threshold is likely to be improper matching of the laser spatial profile with the droplet,
meaning there is some incident light that is not being usefully in-coupled into the droplet.
The optimal height H2 for the LC material deposits produced according to the method of
the present invention, for lasing near the gain maximum, is around 10 m as discussed
above. 1201 The polarization state of the LC laser was experimentally determined and found
to be right-circularly polarized, matching the handedness of the helicoidal structure. This
provides further evidence that the laser mechanism is due to the large density of states
at the edge of the photonic band gap.i The single mode nature of the lasing output
would appear to be a direct consequence of the significant improvement in droplet
uniformity generated by this Inkjet deposition technique.
Example 2
The inventors consider that it is practically useful and advantageous to control the
viscosity, and other properties, such as surface tension, of materials and inks designed
ί o be used in printing. This is particularly true in Inkjet printing where a typical viscosity
requirement for successful printing, or jetting, is under approximately 20 mPa.s, with
surface tension ideally around 20-70 mN/m. See the discussion at the URL:
htip:/ w w.microfab.corn a es/pdfs/ icro et rnf41 accessed 6 May 201 3 .
A convenient method to create suitable conditions for Inkjet printing is to heat the
printhead and/or reservoir, such that the viscosity and surface tension of the material to
be printed is within a suitable range. For many materials, including liquid crystals, the
viscosity has a strong dependency on temperature; the viscosity typically follows an
Arrhenius-type or exponential dependency on the temperature of the material. However,
it is useful to be able to jet at temperatures as close to room temperature as possible
since this reduces the need for complex heating elements in the printhead and allows offthe-
shelf equipment to be used, resulting in lower cost and more widely available
production equipment.
For liquid crystal materials, one particularly suitable way to reduce viscosity at a given
temperature, or to lower the temperature at which successful printing may take place, is
to lower the transition temperature at which the liquid crystal material, or mesophase,
undergoes a phase transition to the ordinary, isotropic, liquid. t is well known in this
technical field that the phase transition temperature, or clearing point, can be controlled
over a wide range (e.g. from well below 0°C to over 200°C) by the formulation of the
mixture and choice of individual components of the LC material.
In this Example 2 , 3% of the chirai dopant R-50 (Merck) was dissolved into the LC E-
100 (Merck, Germany) . The clearing point of the mixture was around 68°C. The mixture
was Inkjet printed using a custom printing rig, consisting of a single-nozzle Microfab
printing device (80 h nozzle diameter) which was used to print the LC deposits. The
LC was deposited onto a wet PVA ( 10% PVA in deionised water; PVA was 0,000 a u
average weight and 85% hydroiysed) film. The wet film was deposited using a standard
K-bar bar coater (RK Print Ltd. UK), with different film thicknesses of 6 , 24 and OOmhΊ
The standing helix alignment was confirmed through optical observation. To reduce the
viscosity of the LC mixture to the jettable limit of 20 mPa.s of the MicroFab device, the
print head was heated and maintained at approximately 77°C, which is above the phase
transition point of around 68°C. A custom pneumatic/vacuum controller was used to
maintain the LC meniscus position at the nozzle and a bipolar waveform was applied to
eject LC material onto the wet PVA film.
This Example therefore demonstrates that it is possible to reduce the printing
temperature of the LC material by about 20°C compared to Example 1, by suitable
control of the composition of the LC ink.
After deposition of the chiral LC has been deposited, it is practically useful to be able to
cross-link the LC material. This improves the environmental and mechanical ruggedness
of the device, and/or allows the addition of further functionality to the device.
To allow cross-linking of the LC material, a suitable quantity of reactive mesogen (a
material that is a liquid crystal but which contains reactive chemical groups such as
acryiafe groups as part of the LC molecule itself to allow joining/cross-linking) is included
into the chiral LC mixture. In principle the concentration of the reactive mesogen can be
from above 0% up to 100% (100% represents the situation where ail the LC molecules
present have cross-linkable groups).
In Example 3 , 3.2% of the chiral dopant R-501 was dissolved into UCL-01 1-K1 (Dai-
Nippon ink Corporation, Japan). The material successfully jetted at print head
temperature of 15°C to be deposited on wet PVA films of thickness between 24-50 mi .
The PVA films were formed as described for Example 1. The deposited material was
then UV cured (365nm, Omnicure S1000, 10 mW/cm2) for 10 minutes.
The standing helix alignment was confirmed through optical observation in a similar
manner as for Example 1.
Example 4
Experimental work has been carried out to assess the effect of timing between formation
of the wet PVA film and subsequent deposition of the LC aliquot by Inkjet printing. The
amount of time between formation of the wet PVA film and subsequent deposition of the
LC aliquot by Inkjet printing is referred to here as "processing time".
Based on this work, there appears to be a preferred lower limit of processing time only
after which successful (i.e. standing helix) alignment of the LC is found to be generated.
The minimum value of the processing time is found to vary with wet film thickness,
composition and processing conditions.
For a 24 m thick wet PVA 0% PVA in H20 ) film, the minimum processing time is just
under 250 seconds. The minimum time reduces as the starting thickness of the wet film
reduces it is observed that the minimum processing time can be further controlled
(reduced) by active drying of the substrate.
For thick or relatively dilute flowable material layers, it is typically necessary to employ
either a relatively long processing time or take active measures (such as active drying) to
reduce the processing time.
Without wishing to be bound by theory, the inventors consider that this phenomenon may
be due to the need for the flowable material layer to settle and reach a suitable
concentration (by drying) in order to provide suitable conditions to promote alignment of
the LC material
The droplet alignment before and after the minimum processing time for a particular film
thickness, composition and processing conditions can be directly visualised with
polarising optical microscopy as discussed above in relation to Example 1.
Comparative Example 2
To fry to improve the deposit uniformity further, experiments were also carried out using
deposition onto surfaces treated with rubbed and baked polyimide alignment layers only,
which promote planar anchoring of the LC in conventional glass cells in these
experiments, the LC material used was as described above and this material was
deposited using similar Inkjet processing conditions to those described above. Instead of
the flowable material layer of Example 1, the LC material was deposited onto a substrate
comprising a planar alignment agent (Merck AM 4278) with uniaxial rubbing direction in
this case, significant wetting of the surface by the droplet was observed both immediately
after deposition and as a function of time, making the devices impractical.
Example 5
A chiral nematic, dye-doped liquid crystal mixture was made, consisting of 4 15% w/w
BDH-1281 dissolved in the nematic liquid crystal BL006 (both obtained from Merck
GmbH, Germany), to which 1% w/w of PM-597 laser dye (Exciton, USA) was added.
The mixture was capillary filled into a test cell, with two plane-parallel glass surfaces
each coated with rubbed polyimide alignment layers, separated by 9 micron spacer
beads, to promote standing helix, or Grandjean, alignment of the chiral nematic liquid
crystal. The alignment was confirmed through polarising optical microscopy observation.
The sample was then optically pumped by a 532nm Nd:YAG laser (Cry Las, GmbH;
focussed by a lens to a spot size around 00 microns) with a pulse energy of
approximately 270 nJ. The optical emission was then recorded using an Ocean Optics
USB2000 fibre-coupled spectrometer. By way of comparison, a 1% w/w PM-597 in
achiral BL008 sample (i.e. no chiral additive) without a photonic band-gap, was optically
pumped under the same conditions to illustrate the fluorescence observed without the
modifying effect of the optical bandgap. The results are shown in Fig. 9 .
As seen in Fig. 9 , the presence of the photonic band-gap modifies the fluorescence
relative to the achiral (no photonic band-gap) sample. This includes, for example, the
creation of local maxima in intensity superimposed on the fluorescence. Note that the
device here operates in pre-threshold mode, and so can be operated at low intensify of
optical pumping. This means that the pump source can be, for example, an LED such as
a flash LED typically provided on a camera phone. Such operation is the subject of
Example 6 , below.
The LC material used in this example is suitable for Inkjet printing onto a fiowabie
material layer, for the formation of discrete LC material deposits as described in other
examples above.
Example 6
A mixture containing 3.5% w/w BDH-1305 (chiral dopant, obtained from Merck GmbH),
1% DCM laser dye (Exciton, USA) in the nematic liquid crystal host E49 (Merck, GmbH)
was filled into a test cell (10 m path length, rubbed polyimide alignment layers). The
sample was then pumped by continuous working LED (450 nm emission wavelength; 1
W optical power; obtained from Luxeon) and the optical emission characteristics
measured.
The emission intensity as a function of wavelength is shown in Fig 0 where a
characteristic profile is shown. The characteristic emission profile, in terms of the
spectral location and intensity, can be controlled readily by altering one or more of, for
example: the position and width of the photonic band-gap; the fluorescence spectrum of
the dye; the pump wavelength; and the power of the excitation source.
The same optical effects are also observable in samples where print deposition is used
once the step of standing heiix alignment, perpendicular to the substrate, is generated.
Conclusion
It is expected that complex and functional laser/photonic device arrays, created by the
inkjef technique of the present invention, will have important potential in a variety of
technological areas. The combination of the high degree of positional control, achieved
through the inkjet deposition process, and control of the iasing emission characteristics,
continuously selectable in the range 450 - 850 n with very narrow iinewidths, permit
further applications of the technology. Arrays of ink-jet printed LC lasers can also be
combined with array-based pumping techniques for the generation of multiple
simultaneous lasers, of arbitrary wavelengths, within a single substrate. Of particular
interest are security applications as described above, and iab-on-a-chip applications
such as fluorescence tag-based bio-assays, for example, whereby arrays of
independently configurable lasers can be printed into sample wells for simultaneous
optical analysis.
The present inventors have demonstrated that the method of the present inventions can
be used to create reproducible multiple low threshold single-mode laser devices by using
precision Inkjet deposition of a LC material, for example a LC lasing medium, onto a
flowable material layer, for example a wet, solution-processible PVA film. Lasers printed
in this way retain all the emission characteristics of samples confined within conventional
glass cells that are pre-treated with rubbed polyimide alignment layers but with the
simplicity and advantages of Inkjet printing. A combination of interfacial interaction,
promoting planar alignment of the LC director, and shear forces originating during the
deposition process promote the standing helix alignment required for photonic band-edge
iasing to occur normal to the substrate, e.g. the glass substrate, on which the flowable
material is deposited.
While the invention has been described in conjunction with the exemplary embodiments
described above, many equivalent modifications and variations will be apparent to those
skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of
the invention set forth above are considered to be illustrative and not limiting. Various
changes to the described embodiments may be made without departing from the spirit
and scope of the invention.
Ail references referred to above are hereby incorporated by reference.
Non-patent literature referred to in the description:
[1] D. K. Yang, X. Y. Huang, Y. M. Zhu, Annu Rev Mater Sci. 1997, 27, 117.
[2] H. Coles, S. Morris, Nat. Photonics. 2010, 4 , 676.
[3] P. J . Collings, M. Hird, introduction to liquid crystals: Chemistry and Physics,
Taylor and Francis, London 1997.
[4] V. . Kopp, B. Fan, H. K. M. Vithana, A. Z . Genack, Opt Lett. 1998, 23, 1707.
[5] C. Mowatt, S. . Morris, M. H. Song, T. D. Wilkinson, R. H. Friend, H. J . Coles, J.
Appl. Phys. 2010, 107, 043101 .
[6] A. Chanishvili, G. Chilaya, G. Petriashviii, R. Barberi, R. Bartolino, G. Cipparrone,
A. azzu la, R. Gimenez, L . Oriol, M. Pinol, Appl. Phys. Lett. 2005, 86, 051 107.
[7] A. Chanishvili, G. Chilaya, G. Petriashviii, R. Barberi, R. Bartolino, G. Cipparrone,
A. Mazzuila, L . Oriol, Adv. Mater. 2004, 16, 791 .
[8] S. M. Morris, P. J . W. Hands, S. Findeisen-Tandel, R. H. Cole, T. D. Wilkinson, H.
J . Coles, Opt. Express. 2008, 16, 18827.
[9] P. J . W. Hands, C. A. Dobson, S. M. Morris, M. M. Qasim, D. J . Gardiner, T. D.
Wilkinson, H. J . Coles, 'Wavelength-tuneable liquid crystal lasers from the visible to the
near-infrared", presented at Proc. SPIE, 201 1, 8 114, 8 1140T
[10] K. Sonoyama, Y. Takanishi, K. Ishikawa, H. Takezoe, Jpn. J. Appl. Phys. 2. 2007,
46, 874.
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Coles, Appl. Phys. Lett 201 , 98.
[13] S. . Morris, A. D Ford, B J Broughton, M. N Pivnenko, H J Coles, "Liquid
crystal lasers: Coherent and incoherent micro-sources", presented at Proc. SPIE, San
Jose, CA, 2005, 5741, 118
[14] K.K.B. Hon, L . Li, i.M. Hatchings, CIRPAnn., 2008, 57, 601
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[16] W.K. Hsiao, S.D. Hoath, G.D. Martin, I.M. Hutchings, J. Imaging Sci. Techno!.,
2009, 53(5), 050304-1
[17] P. S. Drzaic, Liquid Crystal Dispersions, World Scientific, Singapore 1995.
[18] P. S. Drzaic, A. Muller, Liq. Cryst. 1989, 5 , 1467
[19] P. S. Drzaic, R. Wiley, J . McCoy, Proc. SPIE. 1989, 1080, 4 1
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515.

WE CLAIMS:-
1. A method of manufacturing a photonic device, the method comprising the steps
of:
(i) providing an aliquot of a liquid crystal (LC) material of volume V, volume V
being the same volume as that of a sphere of diameter D 1; and
(ii) depositing the aliquot onto the surface of a flowable material layer to form
a liquid crystal deposit, the flowable material and the LC material being
substantially immiscible,
wherein the liquid crystal deposit adopts a deformed shape relative to the shape
of the aliquot due to interaction with the flowable material layer, the liquid crystal
deposit having a maximum length L1, measured in a direction parallel to the
flowable material layer surface before deposition, wherein L 1 is greater than D1.
2 . A method according to claim 1, wherein the generated drop is generated by Inkjet
printing.
3 . A method according to claim 1 or claim 2 , wherein the liquid crystal deposit has a
minimum width W1, measured in a direction parallel to the flowable material layer surface
before deposition, wherein the ratio of W1 to D 1 is greater than 0 .1:1.
4 . A method according to any one of claims 1 to 3 , wherein the deposited drop has a
height H1, measured in a direction perpendicular to the flowable material layer surface
before deposition and L 1 is greater than H1.
5 . A method according to any one of claims 1 to 4 , wherein the ratio of L 1 to D 1 is
not more than 20:1 .
6 . A method according to any one of claims 1 to 5 , wherein the flowable material is a
polymer solution.
7 . A method according to any one of claims 1 to 6 , comprising a step of transforming
the flowable material layer into a support layer.
8 . A method according to claim 7 , wherein the step of transforming the flowable
material layer into a support layer includes the step of shrinking the flowable material
layer.
9 . A method according to claim 7 or claim 8 , wherein after the transformation of the
flowable material layer into a support layer, the ratio of the length L 1 of the LC material
deposit to D 1 is not more than 20: 1.
10. A method according to any one of claims 1 to 9 , wherein the LC material is a
chirai LC material.
11. A method according to any one of claims 1 to 10, wherein the flowable material
contains an alignment component to promote alignment in the LC material.
2 A method according to any one of claims 1 to 11, wherein the flowable material
layer has a substantially constant thickness across the layer, before deposition of the LC
material.
13. A method according to any one of claims 1 to 12 further comprising a step of
providing a protective material layer on top of the LC material deposit.
14. A method according to any one of claims 1 to 13 in which steps (i) and (ii) are
repeated to deposit a series of LC material deposits.
15. A method according to any one of claims 1 to 14, wherein a plurality of aliquots of
the LC material are provided and deposited in a single location on the flowable material
layer.
16. A method according to any one of claims 1 to 15, wherein the flowable material
layer is formed on a substrate by Inkjet deposition of a continuous film, individual drops,
or groups of connected drops of flowable material
17. A method according to any one of claims 1 to 16, wherein the LC material forms a
iasing material.
18. A method according to any one of ciaims 1 to 17, wherein the LC material
includes a fluorescence dye, a fluorescent laser dye, a quantum dot, or other light
harvester or gain additives
19 A photonic device obtained by or obtainable by the method of any one of claims 1
to 17.
20. A laser device obtained by or obtainable by the method of any one of claims 1 to
17.
21. A photonic device having at least one liquid crystal (LC) material deposit formed
on an underlayer, the underlayer having an underlayer surface surrounding the LC
material deposit, wherein the LC material deposit has a maximum length L2, measured in
a direction parallel to the underlayer surface surrounding the LC material deposit, and a
maximum height H2, measured in a direction perpendicular to the underlayer surface
surrounding the LC material deposit, so that L2 is greater than H2, wherein the liquid
crystal deposit is shaped to project above the underlayer surface surrounding the LC
material deposit.
22. A photonic device according to claim 2 1 having a plurality of said LC material
deposits.
23. A photonic device according to claim 2 1 or claim 22, wherein the liquid crystal
deposit is shaped to project below the underlayer surface surrounding the LC material
deposit.
24. A photonic device according to any one of ciaims 2 1 to 23, wherein the ratio of L2
to H2 is in the range 2:1 to 200:1 .
25. Use of a photonic device according to any one of ciaims 19, 21, 22, 23 or 24 in
which the photonic device is subjected to iliumination by a source of electromagnetic
radiation and provides a corresponding response which is detected by a detector or by
observation.
28. Use according to claim 25 wherein the photonic device includes a laser dye and
the source of electromagnetic radiation provides optical pumping sufficient to provide
iasing in the LC material deposit.
27. Use according to claim 25 wherein the photonic device includes a laser dye or a
fluorescent dye, and the device is operated below threshold.
28. Use according to claim 25 wherein the photonic device is illuminated to cause
selective reflection of the iiluminating electromagnetic radiation from the photonic device
based on a photonic bandgap of the photonic device.