Patent Publication Number: US-11646485-B2

Title: Liquid-crystal antenna device having first and second sealing members

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional of U.S. patent application Ser. No. 16/047,127, filed Jul. 27, 2018, now U.S. Pat. No. 10,903,559, which claims the benefit of U.S. Provisional Patent Application No. 62/542,369, filed Aug. 8, 2017, and claims priority of Chinese Patent Application No. 201810146977.2, filed Feb. 12, 2018, the entirety of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     Technical Field 
     The present disclosure relates to a manufacturing method of a liquid-crystal antenna device and a liquid-crystal antenna device manufactured by the method. 
     Description of the Related Art 
     Liquid-crystal molecules can possess both solid and liquid physical properties at the same time, and they have special optical properties and are sensitive to electromagnetic fields. Therefore, liquid-crystal molecules are widely used in various display devices. In recent years, liquid-crystal molecules have also been applied in tunable microwave devices, such as a liquid-crystal antenna device. 
     Specifically, a liquid-crystal antenna device can generate different dielectric coefficients by adjusting the electric field to control the rotation direction of the liquid-crystal molecules, which possess the characteristics of dual-dielectric coefficients. The liquid-crystal antenna device can control the arrangement of liquid-crystal molecules in each liquid-crystal antenna unit via an electrical signal so as to alter the dielectric parameter of each liquid-crystal antenna unit. Therefore, the phase or amplitude of the microwave signal in the liquid-crystal antenna device can be controlled so as to adjust the radiation direction of the microwave signal. 
     However, the requirement of the liquid-crystal antenna device on the injection amount of liquid-crystal molecules is stricter than the conventional liquid-crystal display. The liquid-crystal molecules are slowly absorbed into the device through the capillary principle in the traditional liquid-crystal injection method. The traditional liquid-crystal injection method is more time-consuming and may waste more liquid-crystal materials. 
     On the other hand, the rectangular layout is mostly used for alignment, bonding, assembly and cutting of the traditional liquid-crystal substrates. Although the cutting process can be simplified, the utilization rate of the substrate is not satisfactory. 
     Therefore, developing a method that can further improve the manufacturing quality and efficiency of the liquid-crystal antenna device is still one of the topics that the industry is devoted to researching. 
     SUMMARY 
     In accordance with some embodiments of the present disclosure, a method for manufacturing a liquid-crystal antenna device is provided. The method includes the following steps: (a) providing a first mother substrate, the first mother substrate includes a first region and a second region, the first region has a plurality of first sides, wherein an extension line of at least one of the plurality of first sides divides the second region into a first part and a second part; (b) forming a first electrode layer on the first region and the second region; and (c) cutting the first mother substrate along the plurality of first sides of the first region. 
     In accordance with some embodiments of the present disclosure, a method for manufacturing a liquid-crystal antenna device is provided. The method includes the following steps: (a) providing a first mother substrate, the first mother substrate includes a first region, and the first region has a plurality of first sides; (b) forming a first electrode layer on the first region; (c) disposing a first sealing member on the first region of the first mother substrate to define an active area; (d) dripping a liquid-crystal molecule in the active area; (e) providing a second mother substrate, wherein the first sealing member is disposed between the first mother substrate and the second mother substrate; and (f) cutting the first region of the first mother substrate and the second mother substrate along the plurality of first sides of the first region. 
     In accordance with some embodiments of the present disclosure, a liquid-crystal antenna device is provided. The liquid-crystal antenna device includes a first substrate having a plurality of first sides; a second substrate disposed opposite to the first substrate; a first electrode layer disposed on the first substrate; a second electrode layer disposed on the second substrate; a first sealing member disposed between the first substrate and the second substrate, and the first sealing member, the first substrate and the second substrate define an active area; a liquid-crystal layer filled into the active area; and a second sealing member, wherein a part of the second sealing member protrudes from one of the plurality of first sides, and the second sealing member connects to the first sealing member. 
     A detailed description is given in the following embodiments with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure may be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein: 
         FIG.  1    illustrates a flowchart of a manufacturing method of a liquid-crystal antenna device in accordance with some embodiments of the present disclosure. 
         FIGS.  2 A- 2 G  illustrate the top views of the liquid-crystal antenna device formed in the intermediate stages of the manufacturing method of a liquid-crystal antenna device as shown in  FIG.  1    in accordance with some embodiments of the present disclosure. 
         FIGS.  3 A- 3 D  illustrate the top views of the liquid-crystal antenna device formed in the intermediate stages of a manufacturing method of a liquid-crystal antenna device in accordance with some other embodiments of the present disclosure. 
         FIG.  4    illustrates a cross-sectional view of the liquid-crystal antenna device along the line segment B-B′ in  FIG.  2 G . 
         FIGS.  5 A and  5 B  illustrate the aspects of arrangement of the liquid-crystal antenna devices on the first mother substrate during the manufacture in accordance with some embodiments of the present disclosure. 
         FIG.  5 C  illustrates a partially enlarged part of the region R as shown in  FIG.  5 A . 
         FIGS.  6 - 8    illustrate the aspects of arrangement of the liquid-crystal antenna devices on the first mother substrate during the manufacture in accordance with some embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The manufacturing method of a liquid-crystal antenna device of the present disclosure and the liquid-crystal antenna device manufactured by the method are described in detail in the following description. In the following detailed description, for purposes of explanation, numerous specific details and embodiments are set forth in order to provide a thorough understanding of the present disclosure. The specific elements and configurations described in the following detailed description are set forth in order to clearly describe the present disclosure. It will be apparent, however, that the exemplary embodiments set forth herein are used merely for the purpose of illustration, and the inventive concept may be embodied in various forms without being limited to those exemplary embodiments. In addition, the drawings of different embodiments may use like and/or corresponding numerals to denote like and/or corresponding elements in order to clearly describe the present disclosure. However, the use of like and/or corresponding numerals in the drawings of different embodiments does not suggest any correlation between different embodiments. In addition, in this specification, expressions such as “first material layer disposed on/over a second material layer”, may indicate the direct contact of the first material layer and the second material layer, or it may indicate a non-contact state with one or more intermediate layers between the first material layer and the second material layer. In the above situation, the first material layer may not be in direct contact with the second material layer. 
     It should be noted that the elements or devices in the drawings of the present disclosure may be present in any form or configuration known to those with ordinary skill in the art. In addition, the expressions “a layer overlying another layer”, “a layer is disposed above another layer”, “a layer is disposed on another layer” and “a layer is disposed over another layer” may indicate that the layer is in direct contact with the other layer, or that the layer is not in direct contact with the other layer, there being one or more intermediate layers disposed between the layer and the other layer. 
     In addition, in this specification, relative expressions are used. For example, “lower”, “bottom”, “higher” or “top” are used to describe the position of one element relative to another. It should be appreciated that if a device is flipped upside down, an element that is “lower” will become an element that is “higher”. 
     It should be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers, parts and/or sections, these elements, components, regions, layers, parts and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, part or section from another region, layer or section. Thus, a first element, component, region, layer, part or section discussed below could be termed a second element, component, region, layer, part or section without departing from the teachings of the present disclosure. 
     It should be understood that this description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawings are not drawn to scale. In addition, structures and devices are shown schematically in order to simplify the drawing. 
     The terms “about” and “substantially” typically mean +/−20% of the stated value, more typically +/−10% of the stated value, more typically +/−5% of the stated value, more typically +/−3% of the stated value, more typically +/−2% of the stated value, more typically +/−1% of the stated value and even more typically +/−0.5% of the stated value. The stated value of the present disclosure is an approximate value. When there is no specific description, the stated value includes the meaning of “about” or “substantially”. 
     Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It should be appreciated that, in each case, the term, which is defined in a commonly used dictionary, should be interpreted as having a meaning that conforms to the relative skills of the present disclosure and the background or the context of the present disclosure, and should not be interpreted in an idealized or overly formal manner unless so defined. 
     In addition, in some embodiments of the present disclosure, terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. 
     The manufacturing method of the liquid-crystal antenna device provided by the present disclosure may control the injection amount of the liquid-crystal more accurately and further improve the problem of the liquid-crystal cell gap so as to improve the performance of the liquid-crystal antenna device. In addition, compared with the conventional liquid-crystal injection method that utilizes the capillary principle, the manufacturing method of the liquid-crystal antenna device of the present disclosure may greatly shorten the manufacturing time and improve the manufacturing efficiency. 
     In addition, the present disclosure also provides various aspects of the arrangement of liquid-crystal antenna devices on the mother substrate during the manufacturing process. By using the method of staggered arrangement, the utilization rate of the mother substrate may also be improved efficiently. 
       FIG.  1    illustrates a flowchart of a manufacturing method of a liquid-crystal antenna device  10  in accordance with some embodiments of the present disclosure. It should be understood that additional operations may be provided before, during, and after the processes of the manufacturing method of a liquid-crystal antenna device  10  in some embodiments of the present disclosure. In some embodiments of the present disclosure, some of the operations described below may be replaced or eliminated. In some embodiments of the present disclosure, the order of the operations/processes may be interchangeable. Additional features may be added to the liquid-crystal antenna device in accordance with some embodiments. In some other embodiments of the present disclosure, some of the features of the liquid-crystal antenna device described below may be replaced or eliminated.  FIGS.  2 A- 2 G  illustrate the top views of a liquid-crystal antenna device  200  formed in the intermediate stages of the manufacturing method of a liquid-crystal antenna device  10  as shown in  FIG.  1    in accordance with some embodiments of the present disclosure. 
     First, referring to  FIG.  1    and  FIG.  2 A , the manufacturing method of the liquid-crystal antenna device  10  starts from step  12 . A first mother substrate  100  is provided in step  12 . As shown in  FIG.  2 A , the first mother substrate  100  may include a plurality of first regions  101 . The first region  101  has a plurality of first sides  101   a . A plurality of liquid-crystal antenna devices may be manufactured simultaneously on the first mother substrate  100 , and each first region  101  corresponds to one liquid-crystal antenna device. 
     In some embodiments, the material of the first mother substrate  100  may include, but is not limited to, glass, polyimide (PI), liquid-crystal polymers (LCP), or a combination thereof. The first mother substrate  100  may be formed of rigid substances or elastic substances. In addition, it should be understood that although the shape of the first region  101  is rectangular in the embodiment shown in  FIG.  2 A , the first region  101  may have other shapes in other embodiments, which will be further described with reference to  FIG.  5 A  to  FIG.  8   . 
     Next, referring  FIG.  1   , in step  14 , a first electrode layer  102  (as shown in  FIG.  4   ) is formed in the first region  101  of the first mother substrate  100 . It should be understood that the first electrode layer  102  is omitted in  FIGS.  2 B- 2 G and  4    in order to clearly explain the present disclosure. The first electrode layer  102  may be formed of metallic conductive materials. In some embodiments, the material of the first electrode layer  102  may include, but is not limited to, copper, aluminum, molybdenum, tungsten, gold, chromium, nickel, platinum, copper alloy, aluminum alloy, molybdenum alloy, tungsten alloy, gold alloy, chromium alloy, nickel alloy, platinum alloy, any other suitable conductive materials, or a combination thereof. 
     The first electrode layer  102  may be formed by using one or more deposition, photolithography and etching processes. In some embodiments, the deposition process may include, but is not limited to, a chemical vapor deposition process, a physical vapor deposition process, an electroplating process, an electroless plating process, any other suitable processes, or a combination thereof. The chemical vapor deposition may include, but is not limited to, low-pressure chemical vapor deposition (LPCVD), low-temperature chemical vapor deposition (LTCVD), rapid thermal chemical vapor deposition (RTCVD), plasma enhanced chemical vapor deposition (PECVD), atomic layer deposition (ALD), or any other suitable method. The physical vapor deposition process may include, but is not limited to, sputtering, evaporation, pulsed laser deposition (PLD), or any other suitable processes. In addition, in some embodiments, the photolithography process may include, but is not limited to, photoresist coating (e.g., spin-on coating), soft baking, hard baking, mask aligning, exposure, post-exposure baking, developing the photoresist, rinsing, drying, or any other suitable processes. The etching process may include dry etching process, wet etching process, or any other suitable etching processes. 
     Next referring to  FIG.  1    and  FIG.  2 B , in step  16 , a first sealing member  104  is disposed over the first region  101  of the first mother substrate  100  to define an active area AA of the liquid-crystal antenna device. In other words, the first sealing member  104  surrounds the active area AA. The first sealing member  104  also covers a part of the first electrode layer  102  in accordance with some embodiments. 
     The first sealing member  104  may be formed of adhesive materials. The first mother substrate  100  and a second mother substrate  108  (as shown in  FIG.  2 D ) may be assembled by the first sealing member  104  so as to prevent the liquid-crystal molecules, which will be filled subsequently, from flowing out. The first sealing member  104  may include, but is not limited to, sealant glue, glue dots, any other suitable materials, or a combination thereof. The first sealing member  104  may be formed of a single material or composite materials of the following materials. For example, the material of the first sealing member  104  may include, but is not limited to, polyethylene terephthalate (PET), polyethylene (PE), polyethersulfone (PES), polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy, glass, any other suitable materials, or a combination thereof. In some embodiments, the first sealing member  104  may be a photo-curing or thermal curing sealant. For example, the first sealing member  104  may be a photo-curing sealant (UV light or general visible light), a thermal curing sealant, or a photothermal curing sealant. In addition, in some embodiments, the first sealing member  104  may be formed by coating, spraying, screen printing, any other suitable methods, or a combination thereof, but it is not limited thereto. 
     It should be noted that the first sealing member  104  includes a protruding part  104   p  in accordance with some embodiments. As shown in  FIG.  2 B , the protruding part  104   p  is located within the first region  101 , and the protruding part  104   p  is adjacent to at least one of the first sides  101   a  of the first region  101 . The projection of the protruding part  104   p  is located within the first region  101 . More specifically, the projection of the protruding part  104   p  on the first mother substrate  100  is located within the first region  101 . Although the protruding part  104   p  is provided in a shape similar to “ ” in the embodiment shown in  FIG.  2 B , the protruding part  104   p  may have any other suitable shapes in some other embodiments. For example, the protruding part  104   p  may have a shape similar to “inverted U” in some other embodiment, but is it not limited thereto. In addition, although the first sealing member  104  other than the protruding part  104   p  is substantially rectangular in the embodiment shown in  FIG.  2 B , the shape of the first sealing member  104  is not limited thereto and may be adjusted according to needs. For example, in some embodiments, the first sealing member  104  other than the protruding part  104   p  is substantially circular, semicircular, ¼ circular, triangular, hexagonal, octagonal, decagonal, dodecagonal or any other suitable shapes. 
     Next, referring to  FIG.  1    and  FIG.  2 C , in step  18 , the liquid-crystal molecules  106  are dripped in the active area AA. The liquid-crystal molecules  106  may be dripped into the active area AA surrounded by the first sealing member  104  by a liquid-crystal dispensing apparatus. The amount of the liquid-crystal molecules  106  that is dripped may be adjusted according to the requirement of the liquid-crystal antenna device. In particular, in some embodiments, the amount of liquid-crystal molecules  106  that is dripped may be slightly more than the estimated required amount. Since the slight excess of liquid-crystal molecules  106  can be discharged through the openings formed at the protruding part  104   p  in the subsequent step, an optimum amount of liquid-crystal may be achieved or the gaps of liquid-crystal may be reduced. 
     Next, referring to  FIG.  1    and  FIG.  2 D , in step  20 , a second mother substrate  108  is provided. The second mother substrate  108  covers the first mother substrate  100  so that the first sealing member  104  is disposed between the first mother substrate  100  and the second mother substrate  108 . The first sealing member  104  connects the first mother substrate  100  to the second mother substrate  108 . As described above, the first mother substrate  100  and the second mother substrate  108  can be assembled by the first sealing member  104 . 
     In some embodiments, the material of the second mother substrate  108  may include, but is not limited to, glass, polyimide (PI), liquid-crystal polymers (LCP) or a combination thereof. The material of the first mother substrate  100  is the same as that of the second mother substrate  108  in accordance with some embodiments. The material of the first mother substrate  100  is different from that of the second mother substrate  108  in accordance with some other embodiments. 
     Moreover, the size of the second mother substrate  108  is larger than the size of the first mother substrate  100  in the embodiment shown in  FIG.  2 D . However, it should be understood that this illustration is only for the purpose to clearly distinguish the first mother substrate  100  from the second mother substrate  108 . In fact, the first mother substrate  100  and the second mother substrate  108  may have the same or different sizes according to needs. For example, in some embodiments, a second substrate  108 ′ (not illustrated) may be provided. The second substrate  108 ′ may have substantially the same size and shape as the first region  101 , and a plurality of second substrates  108 ′ may be disposed corresponding to a plurality of first regions  101  of the first mother substrate  100  respectively. In addition, the second mother substrate  108  is omitted in  FIGS.  2 E to  2 G  for clarity. 
     Additionally, a second electrode layer  114  may be formed on a side of the second mother substrate  108  that is close to the first mother substrate  100  (as shown in  FIG.  4   ). The second electrode layer  114  may be formed of metallic conductive materials. In some embodiments, the material of the second electrode layer  114  may include, but is not limited to, copper, aluminum, molybdenum, tungsten, gold, chromium, nickel, platinum, copper alloy, aluminum alloy, molybdenum alloy, tungsten alloy, gold alloy, chromium alloy, nickel alloy, platinum alloy, any other suitable conductive materials, or a combination thereof. 
     The second electrode layer  114  may be formed by using one or more deposition, photolithography and etching processes. In some embodiments, the deposition process may include, but is not limited to, a chemical vapor deposition process, a physical vapor deposition process, an electroplating process, an electroless plating process, any other suitable processes, or a combination thereof. The chemical vapor deposition may include, but is not limited to, low-pressure chemical vapor deposition (LPCVD), low-temperature chemical vapor deposition (LTCVD), rapid thermal chemical vapor deposition (RTCVD), plasma enhanced chemical vapor deposition (PECVD), atomic layer deposition (ALD), or any other suitable method. The physical vapor deposition process may include, but is not limited to, sputtering, evaporation, pulsed laser deposition (PLD), or any other suitable processes. In addition, in some embodiments, the photolithography process may include, but is not limited to, photoresist coating (e.g., spin-on coating), soft baking, hard baking, mask aligning, exposure, post-exposure baking, developing the photoresist, rinsing, drying, or any other suitable processes. The etching process may include dry etching process, wet etching process, or any other suitable etching processes. 
     After the alignment and assembly of the first mother substrate  100  and the second mother substrate  108  are completed, referring to  FIG.  1    and  FIG.  2 E , the first cutting process  22   c  is performed in step  22 . The first mother substrate  100  and the second mother substrate  108  are cut along the first sides  101   a  of the first region  101  in the first cutting process  22   c . As shown in  FIG.  2 E , after the first cutting process  22   c , the protruding part  104   p  is still complete and located in the first region  101 . In other words, the protruding part  104   p  is not cut in the first cutting process  22   c  in accordance with this embodiment. 
     In some embodiments, the first cutting process  22   c  may include, but is not limited to, a mechanical cutting process, a laser cutting process, any other suitable cutting processes, or a combination thereof. In addition, the first mother substrate  100  and the second mother substrate  108  may be cut by the same cutting process in accordance with some embodiments. For example, both the first mother substrate  100  and the second mother substrate  108  may be cut by the first cutting process  22   c . In some other embodiments, the first mother substrate  100  and the second mother substrate  108  may be cut by different cutting processes, and the second mother substrate  108  may be cut to form the second substrate  108 ′ that corresponds to the first region  101  (not illustrated). On the other hand, in some embodiments, after the first cutting process  22   c  is performed, the first region  101  is defined as the first substrate  101 ′. The sidewalls of the first substrate  101 ′ are substantially aligned with the sidewalls of the second substrate  108 ′. However, in some other embodiments, after the first cutting process  22   c  is performed, the size of the first substrate  101 ′ is different from the size of the second substrate  108 ′. That is, the sidewalls of the first substrate  101 ′ and the sidewalls of the second substrate  108 ′ may be not aligned with each other. 
     Next, referring to  FIG.  1    and  FIG.  2 F , a second cutting process  24   c  is performed in step  24 . The first substrate  101 ′ and the second substrate  108 ′ are cut along a first line segment L 1  that penetrates the protruding part  104   p  to form an opening  110  in the second cutting process  24   c . That is, a part of the protruding part  104   p  is cut off in the second cutting process  24   c . The first line segment L 1  may be any line segment that penetrates through the protruding part  104   p  and form an opening at the protruding part  104   p.    
     As described above, the second cutting process  24   c  may include, but is not limited to, a mechanical cutting process, a laser cutting process, any other suitable cutting processes, or a combination thereof. 
     Next, in some embodiments, after step  24 , excess liquid-crystal molecules  106  in the active region AA may be discharged through the opening  110 . Accordingly, the resulting liquid-crystal antenna device may have an optimum amount of liquid crystal. In some embodiments, the liquid-crystal molecules  106  can be discharged through the opening  110  by the way of squeezing, but it is not limited thereto. 
     Next, referring to  FIG.  1    and  FIG.  2 G , in step  26 , the opening  110  is sealed with a second sealing member  112 . In some embodiment, the second sealing member  112  may include, but is not limited to, sealant glue, glue dots, any other suitable materials, or a combination thereof. In some embodiments, the second sealing member  112  may be a photo-curing or thermal curing sealant. For example, the second sealing member  112  may be a photo-curing sealant (UV light or general visible light), a thermal curing sealant, or a photothermal curing sealant. In some embodiments, the second sealing member  112  may be formed of a single material or composite materials of the following materials. For example, the material of the second sealing member  112  may include, but is not limited to, polyethylene terephthalate (PET), polyethylene (PE), polyethersulfone (PES), polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy, glass, any other suitable materials, or a combination thereof. In some embodiments, the material of the second sealing member  112  is the same as the material of the first sealing member  104 . In some embodiments, the material of the second sealing member  112  is different from the material of the first sealing member  104 . 
     As shown in  FIG.  2 G , in the liquid-crystal antenna device  200  manufactured by the above method, a part of the second sealing member  112  protrudes from the sidewalls S of the first substrate  101 ′ and the second substrate  108 ′. The sidewalls S are produced by the second cutting process  24   c . In some embodiments, the second sealing member  112  protrudes from the sidewall S of the first substrate  101 ′ or the sidewall of the second substrate  108 ′ by a distance d 1 , and the distance d 1  is in a range from about 0 mm to about 1 mm. In some embodiments, the second sealing member  112  may be filled at the opening first, and then the excess second sealing member  112  may be scraped off to make the second sealing member  112  protrude from the sidewall of first substrate  101 ′ or the sidewall of the second substrate  108 ′ by the distance d 1 , which is in a range from about 0 mm to about 1 mm. In other words, the distance that the second sealing member  112  protrudes from the first line segment L 1  in a direction X is in a range from about 0 mm to about 1 mm. The direction X is substantially perpendicular to the normal direction (direction Z) of the first substrate  101 ′. 
     As described above, the manufacturing method of the liquid-crystal antenna device  10  includes two cutting processes, the first cutting process  22   c  and the second cutting process  24   c . First, a slight excess of liquid-crystal molecules  106  are filled into the liquid-crystal antenna device  200  and the shape of the liquid-crystal antenna device  200  is roughly defined by the first cutting process  22   c . Then, the excess liquid-crystal molecules  106  in the liquid-crystal antenna device  200  may be discharged by the second cutting process  24   c  so as to have the amount of liquid-crystal more optimized or reduce the generation of a liquid-crystal gap. In addition, the two cutting processes may control the cutting position of the opening for discharging the excess liquid crystal, and may further control the amount of liquid-crystal that is filled into the liquid-crystal antenna device  200 . 
     Referring to  FIGS.  3 A- 3 D ,  FIGS.  3 A- 3 D  illustrate the top views of the liquid-crystal antenna device formed in the intermediate stages of a manufacturing method of a liquid-crystal antenna device  30  in accordance with some other embodiments of the present disclosure. First, referring to  FIG.  3 A , the difference between the embodiments shown in  FIG.  3 A  and  FIG.  2 B  is that a part of the protruding part  104   p  of the first sealing member  104  is located outside the first region  101  in  FIG.  3 A . In this embodiment, the projection of the part of the protruding part  104   p  is located outside the first region  101 . More specifically, the projection of the part of the protruding part  104   p  on the first mother substrate  100  is located outside the first region  101 . In other words, at least partial projection of the protruding part  104   p  on the first mother substrate  100  is located outside the first region  101 . The step shown in  FIG.  3 B  is the same as that in  FIG.  2 C . The liquid-crystal molecules  106  are dripped in the active region AA enclosed by the first sealing member  104  in both  FIG.  3 B  and  FIG.  2 C . The step shown in  FIG.  3 C  is the same as those in  FIG.  2 D . The second mother substrate  108  is provided to cover the first mother substrate  100 , and the first sealing member  104  is disposed between the first mother substrate  100  and the second mother substrate  108  in both  FIG.  3 C  and  FIG.  2 D . The difference between  FIG.  3 D  and  FIG.  2 E  is that the protruding part  104   p  has already been cut in the first cutting process  22   c  in  FIG.  3 D  since the first side  101   a  crosses the protruding part  104   p . Accordingly, the second cutting process  24   c  may be omitted in this embodiment. The subsequent process is the same as that in step  26  and  FIG.  2 G , the excess liquid-crystal molecules  106  in the active region AA may be discharged through the opening  110  and then the opening  110  may be sealed with the second sealing member  112 . The liquid-crystal antenna device  200  is substantially completed at this stage. 
     Next, referring to  FIG.  4   ,  FIG.  4    illustrates a cross-sectional view of the liquid-crystal antenna device  200  along the line segment B-B′ in  FIG.  2 G . It should be understood that additional features may be added to the liquid-crystal antenna device  200  in accordance with some embodiments. In some embodiments, some of the features of the liquid-crystal antenna device  200  described below may be replaced or eliminated. In addition, the same or similar components or elements in above and below contexts are represented by the same or similar reference numerals. The materials, manufacturing methods and functions of these components or elements are the same or similar to those described above, and thus will not be repeated herein. 
     As shown in  FIG.  4   , the liquid-crystal antenna device  200  may include the first substrate  101 ′ and the second substrate  108 ′ that is disposed opposite to the first substrate  101 ′. The liquid-crystal antenna device  200  may also include the first electrode layer  102 , the second electrode layer  114 , the first sealing member  104  and a liquid-crystal layer  106   s . The first electrode layer  102  is disposed on the first substrate  101 ′. As described above, the first electrode layer  102  may be patterned by photolithography, etching processes, and so on. In some embodiments, the patterned first electrode layer  102  may have an opening  116 . 
     Moreover, the second electrode layer  114  may be disposed on the second substrate  108 ′, and the second electrode layer  114  may also be patterned by photolithography, etching process, and so on. In some embodiments, the patterned second electrode layer  114  includes a plurality of parts that are separated from each other, and at least a part thereof corresponds to the opening  116  of the first electrode layer  102 . 
     In some embodiments, the first electrode layer  102  or the second electrode layer  114  may be electrically connected to a corresponding functional circuit (not illustrated). In some embodiments, the functional circuit may be disposed on the second substrate  108 ′ and may be located outside the active area AA that is defined by the first sealing member  104 . Specifically, the functional circuit may apply a voltage to the second electrode layer  114  to change the electric field between the second electrode layer  114  and the first electrode layer  102  and therefore change the arrangement direction (refractive index) of the liquid-crystal molecules  106  that are disposed between the second electrode layer  114  and the first electrode layer  102 . On the other hand, the functional circuit may also apply another voltage to the second electrode layer  114  to transmit the electromagnetic signal through the opening  116 . Moreover, the direction of the electromagnetic signal may be adjusted by the arrangement direction of the liquid-crystal molecules  106 . In some embodiments, the first electrode layer  102  may be electrically floating, grounded, or connected to other circuits (not illustrated). The first electrode layer  102  may be used to shield the electromagnetic signal so that the electromagnetic signal may face toward the opening  116  and enhance the signal/noise ratio of the electromagnetic signal of the liquid-crystal antenna device. 
     However, it should be understood that one with ordinary skill in the art can adjust the amount, the shape or the arrangement (from the top view perspective) of the first electrode layer  102 , the second electrode layer  114  and the corresponding openings  116  according to practical needs, and they are not limited to the aspects shown in  FIG.  4   . 
     In addition, the first sealing member  104  is disposed between the first substrate  101 ′ and the second substrate  108 ′. The first sealing member  104 , the first substrate  101 ′ and the second substrate  108 ′ define an active area AA. In some embodiments, the first sealing member  104  connects the first substrate  101 ′ to the second substrate  108 ′. More specifically, the first sealing member  104  connects the first electrode layer  102  to the second electrode layer  114 . The projection of the first sealing member  104  on the first substrate  101 ′ at least partially overlaps the first electrode layer  102  and also at least partially overlaps the second electrode layer  114 . 
     Moreover, as described above, the liquid-crystal antenna device  200  may further include the second sealing member  112  (as shown in  FIG.  2 G ). The first sealing member  104  may be connected with the second sealing member  112  to form an enclosed area. The liquid-crystal molecules  106  are filled into the enclosed area that is defined by the first sealing member  104 , the second sealing member  112 , the first substrate  101 ′ and the second substrate  108 ′ to form the liquid-crystal layer  106   s . In other words, the first sealing member  104  and the second sealing member  112  are disposed surrounding the liquid-crystal layer  106   s.    
     In addition, the liquid-crystal antenna device  200  may further include at least a spacer element  118  in accordance with some embodiments. The spacer element  118  is disposed between the first substrate  101 ′ and the second substrate  108 ′, and the spacer element  118  may be disposed in the liquid-crystal layer  106   s . The spacer  118  may be used to reinforce the structural strength of the liquid-crystal antenna device  200 . In some embodiments, the spacer elements  118  extend along a direction that is substantially perpendicular to the first substrate  101 ′ or the second substrate  108 ′. 
     The spacer elements  118  may be a ring structure in accordance with some embodiments. In some other embodiments, the spacer element  118  may include a plurality of columnar structures and the columnar structures may be arranged in parallel. In addition, the spacer element  118  may be formed of an insulating material or a conductive material. In some embodiments, the material of the spacer element  118  may include, but is not limited to, copper, silver, gold, copper alloys, silver alloys, gold alloys, or a combination thereof. In some embodiments, the spacer element  118  may be formed of a single material or composite materials. For example, in other embodiments, the material of the spacer element  118  may include, but is not limited to, polyethylene terephthalate (PET), polyethylene (PE), polyethersulfone (PES), polycarbonate (PC), polymethylmethacrylate (PMMA), glass, any other suitable materials, or a combination thereof. In some embodiments, the spacer element  118  may be adhesive. 
     Next, referring to  FIG.  5 A ,  FIG.  5 A  illustrates the aspects of arrangement of the liquid-crystal antenna devices  200  on the first mother substrate  100  during the manufacture in accordance with some embodiments of the present disclosure. As described above, the first mother substrate  100  may include a plurality of regions corresponding to where the liquid-crystal antenna devices  200  that are subsequently formed. In this embodiment, the first mother substrate  100  includes the first region  101  and the second region  201 . The first region  101  and the second region  201  are arranged in a staggered manner. The first region  101  has a plurality of first sides  101   a . Therefore, an extension line of at least one of the first sides  101   a  may pass through the second region  201 , that is to say, the extension line of the at least one of the first sides  101   a  may divide the second region  201  into two parts. 
     Specifically, as shown in  FIG.  5 A , the extension line L 2  of the first side  101   a  of the first region  101  divides the second region  201  into a first part  201   c  and a second part  201   e . Similarly, the extension line L 3  of the first side  101   a  of the first region  101  divides the second region  201  into a third part  201   f  and a fourth part  201   d  (as shown in  FIG.  5 B ). In addition, the area of the first region  101  is substantially the same as the area of the second region  201  in accordance with some embodiments. However, it should be understood that although only one first region  101  and one second region  201  are illustrated in the figure as an example, the first mother substrate  100  may actually have a plurality of first regions  101  and a plurality of second regions  201 . 
     Next, referring to  FIG.  5 C ,  FIG.  5 C  illustrates a partially enlarged part of the region R as shown in  FIG.  5 A . As shown in  FIG.  5 C , the second region  201  may have a plurality of second sides  201   a ,  201   a ′,  201   a ″. The second side  201   a ′ is connected to the second side  201   a  to form an obtuse angle θ 1 , and the second side  201   a ′ is connected to the second side  201   a ″ to form an obtuse angle θ 2 . In some embodiments, the obtuse angle this substantially equal to the obtuse angle θ 2 . In some other embodiments, the obtuse angle θ 1  is not equal to the obtuse angle θ 2 . The extension line L 4  of the second side  201   a  and the extension line L 5  of the second side  201   a ″ form a virtual triangle T with the second side  201   a ′. The virtual triangle T partially overlaps with the first region  101 . In some embodiments, the virtual triangle T may be a right triangle, an equilateral triangle, or a regular triangle, but is not limited thereto. 
     In some embodiments, the minimum distance d 2  between the second side  201   a ′ of the second region  201  and the first region  101  is in a range from about 0.5 mm to about 30 mm. it should be noted that, if the minimum distance d 2  between the second side  201   a ′ of the second region  201  and the first region  101  is too small (for example, less than 0.5 mm), the distance between the first region  101  and the second region  201  may be too close. This may make the subsequent cutting process of the substrate become more difficult, or even result in cracks of the substrate. 
     In addition, the first region  101  and the second region  201  may have any suitable shape, as long as at least one side of the shape may form an obtuse angle with the two adjacent sides. As shown in  FIGS.  6 - 8   , in some embodiments, the first region  101  and the second region  201  may be octagons (as shown in  FIG.  6   ), decagons (as shown in  FIG.  7   ), or dodecagons ( FIG.  8   ), but they are not limited thereto. In these embodiments, the first region  101  and the second region  201  are arranged in a staggered manner. Therefore, the extension line L 2  or the extension line L 3  of the first side  101   a  of the first region  101  also divides the second region  201  into two parts. The extension line L 4  and the extension line L 5  of the second side  201   a  and the second side  201   a ″ also form a virtual triangle T with the second side  201   a ′, and the virtual triangle T partially overlaps with the first region  101 . 
     Compared with the commonly used rectangular arrangement, the manufacturing method of the liquid-crystal antenna device as described above can effectively improve the utilization rate of the substrate by using the non-rectangular and staggered arrangement. More specifically, the utilization rate of the substrate can be increased by about 30% to about 100%. 
     In summary, the method for manufacturing the liquid-crystal antenna device provided in the present disclosure may have both advantages of the traditional liquid-crystal injection method and the one drop filling (ODF) method. The amount of liquid-crystal injected can be precisely controlled so as to achieve the optimum amount of liquid-crystal or reduce the generation of a liquid-crystal gap. The performance of the liquid-crystal antenna device can be enhanced accordingly. In addition, the present disclosure also provides multiple arrangements of the liquid-crystal antenna device during the process. The non-rectangular staggered arrangement can effectively improve the utilization of the substrate. 
     Although some embodiments of the present disclosure and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. For example, it will be readily understood by one of ordinary skill in the art that many of the features, functions, processes, and materials described herein may be varied while remaining within the scope of the present disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.