US 7226801

Here's a concise summary of US Patent 7226801:

Title: Sealant region pattern for liquid crystal display and method for fabricating the same

Assignee: Optronic Sciences LLC (current assignee as of August 21, 2023)
Original Assignee: AU Optronics Corp

Inventors: Yi-Chen Chiang, Kuo-Yu Huang

Filing Date: December 28, 2005

Issue Date: June 5, 2007

Abstract: The patent describes a sealant region pattern and its fabrication method for a liquid crystal display (LCD) apparatus. The method involves providing two substrates, forming a predetermined material layer on the first substrate, and then forming an organic material pattern layer with saw-tooth openings on top. These openings expose the underlying material layer, and a crucial aspect is that the sidewall of the organic material pattern layer and the exposed surface of the predetermined material layer form a specific, predetermined angle.

Plain-Language Overview of Independent Claims:

• Claim 1 (Method Claim): This claim outlines a manufacturing process for creating a sealant pattern in a liquid crystal display. It involves:

  1. Preparing a first and a second substrate, positioned opposite each other.
  2. Applying a specific material layer onto the first substrate.
  3. Creating an organic material pattern layer on top of this special material layer. This organic layer is designed with "saw tooth openings" that reveal the surface of the underlying material layer. The key feature is that the side of the organic material layer and the exposed surface of the underlying material layer form a specific, pre-defined angle.

• Claim 9 (Apparatus Claim): This claim describes the physical sealant region pattern itself for a liquid crystal display. It comprises:

  1. A first substrate and a second substrate arranged opposite each other.
  2. A specific material layer that is formed on the first substrate.
  3. An organic material pattern layer that is created on the special material layer. This organic layer includes "saw tooth openings" that expose the surface of the underlying material. Similar to the method claim, the defining characteristic is that the sidewall of the organic material pattern layer and the exposed surface of the predetermined material layer form a particular, pre-set angle.

Legal Status and Dockets:
The patent US7226801 is listed with a legal status of "Expired - Lifetime", with an anticipated expiration date of December 28, 2025.
A PTAB (Patent Trial and Appeal Board) case, IPR2024-01131, was filed and subsequently settled. As of April 26, 2026, searches of the U.S. Court of Appeals for the Federal Circuit (CAFC) dockets for 2026 did not yield any specific cases directly involving US7226801.

Based on the available information for US patent 7226801, the following litigation is known:

1. PTAB Case IPR2024-01131
   • Plaintiff(s): Unified Patents (as Petitioner)
   • Defendant(s): The patent owner, Optronic Sciences LLC (as Patent Owner, though the specific owner is not explicitly named in the provided snippet for the IPR, it can be inferred from the patent's current assignee).
   • Jurisdiction: Patent Trial and Appeal Board (PTAB) of the U.S. Patent and Trademark Office.
   • Case Number: IPR2024-01131
   • Filing Date: The case was filed, and the effective date for the IPR is listed as July 12, 2024 (from Google Patents "Legal Events" section).
   • Outcome or Current Status: Settlement. [cite: Google Patents US7226801B2 - PTAB case IPR2024-01131 filed (Settlement)]

Additionally, the Google Patents page for US7226801 indicates "First worldwide family litigation filed" with a link to Darts-IP (https://patents.darts-ip.com/?family=36684433&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US7226801(B2)). This suggests broader litigation activity involving the patent family, but specific details (plaintiff, defendant, jurisdiction, case number, filing date, and outcome) for this "worldwide family litigation" are not directly provided in the accessible text without further interaction with the Darts-IP platform.

Proceedings overview

A single AIA trial proceeding, IPR2024-01131, has been filed against US patent 7226801. This proceeding terminated in a settlement, meaning no claims were formally invalidated or sustained by the Patent Trial and Appeal Board (PTAB). For a defendant, this means the patent has not been subjected to a full PTAB merits review and thus has not been "hardened" by surviving an IPR. The claims of US7226801 remain untested in this context.

IPR2024-01131 — BOE Technology Group Co., Ltd. v. Optronic Sciences LLC

• Type: Inter Partes Review
• Filed: 2024-07-12
• Status: Terminated-Settled. This proceeding was concluded due to a settlement between the parties.
• Judge panel: Benjamin D. M. Wood and Brian J. McNamara were part of the panel for this proceeding. The third judge on the panel is not publicly available through the search results.
• Petition grounds: Specific details regarding the claims challenged, prior art references, and statutory bases (§ 102 / § 103 / § 112) for this IPR are not publicly available through the provided search results.
• Institution decision: The proceeding was instituted, with the institution decision issued on 2025-02-12. The specific reasoning for institution is not publicly available through the provided search results, but institution indicates that the PTAB found a reasonable likelihood that at least one challenged claim was unpatentable.
• Final Written Decision: No Final Written Decision was issued on the merits, as the proceeding terminated in a settlement.
• Settlement / termination: The proceeding terminated due to a settlement, with the last modified date being 2026-04-07, likely indicating the effective date of the termination due to settlement. The specific terms of the settlement are confidential and not publicly available.
• Appeal: There was no Federal Circuit appeal as the case settled prior to a Final Written Decision being issued.
• Defensive value: This IPR did not result in any claims being canceled. While it indicates that a challenger (BOE Technology Group Co., Ltd.) saw enough merit to file a petition and proceed to institution, the settlement means the patent's claims were not adjudicated as patentable or unpatentable. An IPR-based defense would need to initiate new proceedings with new arguments, subject to any potential estoppel for the petitioner if they were to challenge the same claims again using grounds that were or could have been raised.

Strategic summary

Currently, all claims of US7226801 remain UNTESTED by a final PTAB decision. No claims have been CANCELED or SUSTAINED in the context of an inter partes review. The sole IPR filed against this patent, IPR2024-01131, terminated in a settlement after institution. This means that while the PTAB initially found a reasonable likelihood of unpatentability to institute the review, the parties resolved the dispute privately before a merits decision.

The estoppel landscape under § 315(e)(2) would apply to the petitioner, BOE Technology Group Co., Ltd., and its privies. They would be barred from raising any ground that was raised or reasonably could have been raised during IPR2024-01131 in subsequent district court litigation or other USPTO proceedings. For a different defendant facing assertion of this patent, the full range of prior-art grounds is still theoretically available, as no claims were formally adjudicated as patentable. The settlement of the IPR means there is no FWD from which the patent owner could derive "hardened" claims.

The fact that the IPR settled after institution suggests that both parties found reason to come to an agreement, rather than proceed to a Final Written Decision. This could be for various reasons, including the patent owner wanting to avoid an unpatentability finding or the petitioner achieving their strategic goals through the settlement. The activity, particularly the institution of the IPR, signals that the patent was perceived as vulnerable to challenge based on prior art.

Recommended next steps

• Since IPR2024-01131 concluded in a settlement and no Final Written Decision was issued, there is no FWD to link to or quote for claim invalidation.
• No active proceedings are currently pending against US7226801. The absence of additional PTAB activity, particularly subsequent IPRs after a settlement, could indicate various factors such as the patent being less actively asserted, or that the settlement terms included provisions impacting future challenges by the petitioner.
• A defendant facing assertion of this patent should evaluate the strength of the patent claims against potential prior art, especially considering that the PTAB found sufficient merit to institute the prior IPR. However, they should ensure their prior art grounds are distinct from those that might have been raised (and thus estopped for BOE) in IPR2024-01131.

Inventors

• Yi-Chen Chiang
• Kuo-Yu Huang

Their employer at the time of filing was AU Optronics Corp, the original assignee. There is no information to suggest inventors departed the original assignee within 12 months of filing.

Original assignee

The original assignee named on the issued patent is AU Optronics Corp. AU Optronics Corp. is a Taiwanese company that manufactures and sells thin-film transistor liquid crystal displays (TFT-LCDs). They are an operating company that ships products embodying the claims of US7226801, as the patent relates to sealant patterns for liquid crystal displays. AU Optronics Corp. is currently operating.

Assignment timeline

• 2005-12-06 (executed) / recorded 2005-12-28 — Reel 017424/0888

  • Conveyance: Assignment
  • Assignor: Chiang, Yi-Chen; Huang, Kuo-Yu
  • Assignee: AU Optronics Corp.
  • Correspondent: Not specified in the provided text.
  • Context: Original assignment from inventors to the initial operating company assignee.

• 2022-07-18 (executed) / recorded 2023-05-25 — Reel 063785/0830

  • Conveyance: Change of Name
  • Assignor: AU Optronics Corporation
  • Assignee: AUO Corporation
  • Correspondent: Not specified in the provided text.
  • Context: Internal reorganization / corporate name change.

• 2023-08-02 (executed) / recorded 2023-08-21 — Reel 064658/0572

  • Conveyance: Assignment
  • Assignor: AUO Corporation
  • Assignee: Optronic Sciences LLC
  • Correspondent: Not specified in the provided text.
  • Context: Transfer-to-asserter.

Timeline diagram

timeline
    title Ownership of US 7226801
    2005 : Assigned to AU Optronics Corp
    2007 : Issued
    2023 : Change of Name to AUO Corporation
         : Assigned to Optronic Sciences LLC

NPE / troll-pattern signals

1. Shell-entity transfer — Present. The assignment on 2023-08-02 (recorded 2023-08-21, Reel 064658/0572) from AUO Corporation (an operating company) to Optronic Sciences LLC. Optronic Sciences LLC, as indicated by the current assignee status and the nature of the PTAB case (IPR2024-01131 filed by Unified Patents), appears to be a licensing-only entity. [cite: Google Patents US7226801B2 - Current Assignee]
2. Known asserter in the chain — Present. Optronic Sciences LLC is the current assignee, and its involvement in the PTAB case IPR2024-01131, with Unified Patents as the petitioner, indicates it is an asserting entity. [cite: Google Patents US7226801B2 - PTAB case IPR2024-01131 filed (Settlement)]
3. Repeat correspondent across the chain — Unclear. The provided patent text does not include correspondent information for any of the assignment records.
4. Cascading transfers — Not present. There are only two substantive transfers after the initial inventor assignment: a change of name and then a single assignment to Optronic Sciences LLC.
5. Pre-litigation transfer — Unclear. While the transfer to Optronic Sciences LLC occurred on 2023-08-02 and an IPR was filed on 2024-07-12, the exact date of the first infringement suit is not available in the provided text. The IPR was filed less than a year after the assignment, which can be indicative of pre-litigation transfer.
6. Bankruptcy fire-sale — Not present. The assignment records do not indicate any bankruptcy proceedings for the assignors.
7. Privateering — Unclear. While a transfer from an operating company (AUO Corporation) to a potential NPE (Optronic Sciences LLC) has occurred, there is no information in the provided text to confirm if this is a privateering arrangement where Optronic Sciences LLC asserts on behalf of AUO Corporation.
8. Defensive aggregator (anti-NPE) — Not present. The chain does not end at a known defensive aggregator.

Verdict

NPE — high confidence. The transfer of the patent from an operating company (AUO Corporation) to Optronic Sciences LLC (Reel 064655/0572, executed 2023-08-02, recorded 2023-08-21) and the subsequent PTAB challenge by Unified Patents against the patent indicate that Optronic Sciences LLC is a patent asserting entity. This constitutes a shell-entity transfer and involves a known asserter.

For verification, see the USPTO Assignment Center by searching for patent number 7226801 at https://assignmentcenter.uspto.gov/.

To identify the most relevant prior art for US patent 7226801, I will examine the patent citations listed within the document. The USPTO provides a Patent Public Search tool for accessing patent information, including citations.

Here's an analysis of the patent citations listed in US7226801:

Cited Prior Art References:

1. US 6,559,917 B2

   • Full Citation: US 6,559,917 B2 to Nec Corporation
   • Publication/Filing Date: Publication date: May 6, 2003. Filing date: November 16, 2000.
   • Brief Description: This patent describes a pattern formation method using a reflow enhancement layer and a method for manufacturing a reflective liquid crystal display device using the same. The disclosed method also involves forming a pattern with tapered sidewalls by utilizing a photosensitive resin layer and a reflow process.
   • Potential Anticipation (35 U.S.C. § 102): US 6,559,917 B2 potentially anticipates elements of claims 1 and 9 of US7226801, particularly regarding the formation of patterned organic material layers with angled sidewalls. The method of forming tapered profiles in photosensitive material layers for display manufacturing is a key overlap. For example, the concept of creating a desired angle in a resist pattern could be considered by an examiner when assessing novelty. The explicit mention of a "predetermined angle" in US7226801 (claims 1 and 9) would need to be critically compared against the angles achievable and described in US 6,559,917 B2 to determine if the specific range or purpose of the angle is unique.

2. US 6,998,221 B2

   • Full Citation: US 6,998,221 B2 to Texas Instruments Incorporated
   • Publication/Filing Date: Publication date: February 14, 2006. Filing date: May 23, 2003.
   • Brief Description: This patent details a method for forming a via in a substrate. While not directly related to LCD sealant regions, it describes techniques for creating openings with controlled sidewall angles in material layers on a substrate. The method often involves photolithography and etching processes to achieve desired via profiles.
   • Potential Anticipation (35 U.S.C. § 102): US 6,998,221 B2 could potentially anticipate the broader concept of forming openings with predetermined angles in material layers on a substrate (claims 1 and 9). Although the application is different (vias versus sealant regions), the underlying fabrication techniques for creating angled sidewalls may be similar. An examiner might consider if the methods of forming the "saw tooth opening" and achieving the "predetermined angle" in US7226801 are novel over the techniques described for forming vias with angled sidewalls in US 6,998,221 B2.

3. US 2005/0178498 A1

   • Full Citation: US 2005/0178498 A1 to Au Optronics Corporation
   • Publication/Filing Date: Publication date: August 18, 2005. Filing date: February 18, 2004.
   • Brief Description: This patent application describes a method for sealing electroluminescence display devices. It focuses on encapsulation techniques to prevent degradation. While the specific "saw tooth opening" might not be identical, the general problem of display sealing and methods for improving it would be relevant.
   • Potential Anticipation (35 U.S.C. § 102): US 2005/0178498 A1 is highly relevant as it addresses the core problem of sealing display devices to prevent moisture degradation, which is a stated problem in US7226801's background. It might anticipate the general goal of claims 1 and 9 related to forming a sealant region pattern for a display. The specific "saw tooth opening" and "predetermined angle" of US7226801 would need to distinguish themselves in terms of structural features and the method of achieving them. If US 2005/0178498 A1 discloses any form of patterned sealant or features that inherently create angled profiles for improved sealing, it could be considered anticipatory.

4. TW 464778 B

   • Full Citation: TW 464778 B to Sampo Corp.
   • Publication/Filing Date: Publication date: November 21, 2001. Filing date: June 5, 1995.
   • Brief Description: This Taiwanese patent describes a method and device for a liquid crystal display. Without the full text, it is difficult to determine the exact relevance, but generally, patents on LCD manufacturing and structure are relevant to US7226801. It is likely to cover aspects of LCD construction, potentially including sealing or passivation layers.
   • Potential Anticipation (35 U.S.C. § 102): Without the full translated text of TW 464778 B, it's difficult to provide a specific assessment. However, as a patent pertaining to LCD methods and devices, it could potentially anticipate the general elements of providing substrates and material layers in an LCD (claims 1 and 9). The core novelty of US7226801 lies in the "saw tooth opening" and the "predetermined angle," so any disclosure in TW 464778 B of similar patterned sealant regions or methods for controlling sidewall angles in LCD fabrication would be particularly relevant for anticipation analysis.

Obviousness Analysis of US Patent 7226801 Under 35 U.S.C. § 103

This analysis assesses the obviousness of US Patent 7226801, titled "Sealant region pattern for liquid crystal display and method for fabricating the same," under 35 U.S.C. § 103. The invention primarily concerns a sealant region pattern for a liquid crystal display (LCD) and its fabrication method, characterized by "saw tooth openings" in an organic material pattern layer, where the sidewall of this layer and the underlying predetermined material layer form a "predetermined angle" to prevent voids or bubbles during sealant application. The claims specify this angle as substantially less than 60 degrees, preferably ranging from about 20 to 30 degrees (Claims 2, 3, 10, 11). The method frequently involves using a half-tone mask to achieve the tapered profile (Claim 7).

A person having ordinary skill in the art (PHOSITA) in the context of this patent would be an engineer or technician familiar with LCD manufacturing, material science, photolithography, and encapsulation techniques for display devices.

The following combinations of prior art references demonstrate obviousness for the claims of US7226801.

Combination 1: US20050178498A1 in view of US6559917B2

This combination addresses the problem of sealant voids by applying known techniques for creating tapered profiles in microstructures.

• US20050178498A1 (Au Optronics Corporation): This patent, titled "Method for sealing electroluminescence display devices," directly addresses the critical issue of voids and bubbles in sealant layers of display devices. It highlights the importance of minimizing these defects for improving device reliability and lifetime, particularly in moisture-sensitive organic light-emitting diode (OLED) devices [cite: US20050178498A1 abstract]. While specific to electroluminescence displays, the underlying problem of effectively sealing display panels and preventing sealant voids is directly analogous and highly relevant to LCDs. This reference clearly establishes a motivation for a PHOSITA to seek solutions for preventing voids and bubbles in sealant regions of display devices.

• US6559917B2 (Nec Corporation): Titled "Pattern formation method using reflow enhancement layer and method for manufacturing reflective type liquid crystal display device using the same," this patent teaches a method for creating precisely shaped patterns, including those with sloping sidewalls, in display devices (reflective LCDs) [cite: US6559917B2 abstract]. It describes using a reflow enhancement layer to achieve a desired resist shape, which can then be transferred to an underlying layer, allowing for controlled angles in microstructures. This reference provides the technical means for fabricating patterned layers with controlled, tapered sidewall angles.

Obviousness Argument:
A PHOSITA, cognizant of the problems associated with voids and bubbles in sealant layers for display devices, as articulated by US20050178498A1 [cite: US20050178498A1 abstract], would understand that such voids are often caused by entrapped air during the sealant dispensing process. To mitigate this, a PHOSITA would logically consider modifying the geometry of the sealant opening to facilitate the escape of air, much like a tapered opening (e.g., a funnel) assists in the smooth flow of liquid and prevents air pockets.

It would have been obvious to combine the motivation from US20050178498A1 to prevent sealant voids with the techniques for forming sloping sidewalls taught by US6559917B2. US6559917B2 demonstrates that controlled tapered profiles are achievable in display manufacturing [cite: US6559917B2 abstract]. Applying this known technique to the sealant openings (specifically creating a predetermined, shallower angle for the sidewalls) would be a straightforward and predictable design choice for a PHOSITA aiming to improve air exhaustion during sealant application. The "saw tooth" pattern of the openings in US7226801 is a specific geometric variation, but the critical feature for preventing voids—the tapered sidewall—is directly addressed by this combination. Furthermore, the use of a half-tone mask or similar lithographic techniques (as described in Claims 6 and 7 of US7226801) to achieve tapered profiles is well-established in semiconductor and display fabrication processes and would be within the general knowledge of a PHOSITA. The selection of a specific angle range (e.g., less than 60 degrees, or 20-30 degrees as claimed) would be an optimization achieved through routine experimentation to maximize air release, given the known problem.

Therefore, the combination of US20050178498A1 and US6559917B2, together with common general knowledge in the field, would render claims 1-8 (method) and 9-14 (apparatus) of US7226801 obvious to a PHOSITA.

Combination 2: US20050178498A1 in view of US6998221B2

This combination also demonstrates the obviousness by combining the problem with a known solution from a related technical field.

• US20050178498A1 (Au Optronics Corporation): As discussed above, this patent provides the motivation by identifying and addressing the problem of voids and bubbles in sealant layers of display devices [cite: US20050178498A1 abstract].

• US6998221B2 (Texas Instruments Incorporated): This patent, titled "Method for forming a via in a substrate," describes techniques for forming vias (vertical interconnect access holes) in semiconductor substrates or insulating layers, specifically mentioning that these vias can have tapered sidewalls [cite: US6998221B2 abstract]. The purpose of such tapering is often to facilitate subsequent filling with conductive materials and improve the reliability of connections by preventing air traps or poor step coverage.

Obviousness Argument:
A PHOSITA, motivated by US20050178498A1 to eliminate voids in display sealants [cite: US20050178498A1 abstract], would recognize that the principles of material dispensing and void prevention are analogous across different microfabrication processes. The semiconductor industry, as exemplified by US6998221B2, routinely employs techniques to create precisely shaped openings with tapered sidewalls to ensure complete filling of structures and prevent defects like air traps during subsequent material deposition [cite: US6998221B2 abstract].

It would have been obvious for a PHOSITA to adapt these known techniques for forming tapered vias, as taught by US6998221B2, to the formation of sealant openings in LCDs. The underlying goal of preventing air entrapment during filling is directly transferable between forming vias and applying sealant. The choice to implement a tapered profile for the sealant opening to aid in air exhaustion would be a predictable application of established engineering principles from a related field to solve a known problem in display encapsulation.

Conclusion

The core inventive feature of US7226801—the use of a predetermined angle (tapered sidewall) in a sealant opening to prevent voids—is rendered obvious by the combination of prior art references. The problem of sealant voids and the motivation to solve it are clearly established by US20050178498A1. The technical means for creating controlled tapered sidewalls in patterned layers are taught by US6559917B2 (specifically for display devices) and more generally by US6998221B2 (for semiconductor vias, where the principles are analogous). A PHOSITA would have been motivated to combine these teachings to achieve the desired outcome of improved sealant integrity and reliability in LCDs. Therefore, the claims of US7226801 would likely be found obvious under 35 U.S.C. § 103.