Display panel, display device, and method of manufacturing display panel

Abstract

This invention provides a display panel, a display device, and a method for manufacturing the display panel. The display panel has a display area with multiple pixel regions of different colors. The display panel includes: a color filter substrate; an array substrate disposed opposite to the color filter substrate; and multiple main spacers located on the side of the color filter substrate facing the array substrate. Each main spacer includes a first support portion and a second support portion, the second support portion being connected to the color filter substrate, and the first support portion located on the side of the second support portion facing away from the color filter substrate. The surface area of ​​the side of the first support portion facing away from the color filter substrate is smaller than the surface area of ​​the side of the second support portion facing away from the color filter substrate.

Description

Technical Field

[0001] This invention relates to the field of display technology, and in particular to a display panel, a display device, and a method for manufacturing the display panel. Background Technology

[0002] In related technologies, thin-film transistor liquid crystal displays (TFT-LCDs) include an array substrate and a color filter substrate positioned opposite each other, with a liquid crystal layer disposed between them. To ensure the uniformity of the liquid crystal layer thickness, a photo spacer (PS) is typically placed on the side of the color filter substrate facing the array substrate for support. Since the top surface of the photo spacer needs to be in direct contact with the array substrate, the size of the top surface of the photo spacer has a significant impact on the overall pressing performance of the display panel.

[0003] In related technologies, spacers have a single, fixed-size top surface. When the top surface size is large, the static friction between the spacer and the array substrate is large after being compressed, making it difficult to rebound and easily causing uneven pressing (T-DNU). In addition, since the display panel needs to be placed in a cassette (CST) during the production process and supported by cassette pins (CST pins), when the top surface size of the spacer is small, the support strength of the spacer is low. Under the action of gravity for a long time, the display panel is prone to large plastic deformation, resulting in cassette failure (CST Mura), which leads to an increased NG (non-conforming) rate and a decrease in the shipment rate.

[0004] In other words, the spacers used in the relevant technologies, regardless of size, cannot simultaneously reduce the risk of uneven pressure on the display panel and the risk of malfunctioning clips. Summary of the Invention

[0005] The purpose of this invention is to provide a display panel, a display device, and a method for manufacturing the display panel, so as to simultaneously reduce the risks of uneven pressure on the display panel and the risk of malfunctioning clips. The specific technical solution is as follows:

[0006] An embodiment of the first aspect of this application provides a display panel having a display area having a plurality of pixel areas of different colors; the display panel includes: a color filter substrate; an array substrate disposed opposite to the color filter substrate; a plurality of main spacers located on the side of the color filter substrate facing the array substrate, each of the main spacers including a first support portion and a second support portion, the second support portion being connected to the color filter substrate, the first support portion being located on the side of the second support portion away from the color filter substrate; the surface area of ​​the side of the first support portion away from the color filter substrate is smaller than the surface area of ​​the side of the second support portion away from the color filter substrate.

[0007] In some embodiments of this application, the color filter substrate includes a black matrix layer, which defines a plurality of first openings, a plurality of second openings, and a plurality of third openings in the display area. The first openings correspond to blue pixel areas, the second openings correspond to green pixel areas, and the third openings correspond to red pixel areas.

[0008] The projection of the main spacer onto the black matrix layer is located between two adjacent first openings.

[0009] In some embodiments of this application, the array substrate includes multiple scan lines and multiple data lines, the scan lines and the data lines intersecting perpendicularly to define multiple pixel units, and the pixel units correspond one-to-one with the pixel regions;

[0010] The projection of the main spacer onto the array substrate is within the range of the scan line.

[0011] In some embodiments of this application, the display panel further includes a plurality of auxiliary spacers; the plurality of auxiliary spacers are located on the side of the color filter substrate facing the array substrate, and the height of the auxiliary spacers is less than that of the main spacers in the thickness direction of the display panel.

[0012] In some embodiments of this application, the projection of the auxiliary spacer onto the black matrix layer is located between two adjacent first openings or between two adjacent third openings.

[0013] In some embodiments of this application, a main spacer or an auxiliary spacer is provided between every two adjacent first openings, and an auxiliary spacer is provided between every two adjacent third openings; and the number of auxiliary spacers is greater than the number of main spacers.

[0014] In some embodiments of this application, the array substrate further includes a plurality of uniformly distributed thin-film transistors, each corresponding to a pixel unit; the projections of the main spacer and the auxiliary spacer on the array substrate are located within the range of the scan lines and do not overlap with the thin-film transistors.

[0015] In some embodiments of this application, H1 > C × H3; where H1 is the height of the first support in the thickness direction of the display panel, C is the center compression ratio of the main spacer, and H3 is the total height of the main spacer in the thickness direction of the display panel.

[0016] In some embodiments of this application, H1 < C × H3 + 0.02 × CG, where CG is the thickness value of the display panel.

[0017] In some embodiments of this application, the first support portion is a cylindrical structure, the first support portion extends along the thickness direction of the display panel, and the diameter of the first support portion is greater than or equal to 10 μm and less than or equal to 14 μm.

[0018] In some embodiments of this application, the second support portion is a cylindrical structure, the second support portion extends along the thickness direction of the display panel, the diameter of the second support portion is larger than that of the first support portion, the connecting surface of the second support portion and the first support portion constitutes the shoulder of the main spacer, the difference between the distance between two adjacent first openings and the diameter of the second support portion is greater than 40 μm, or the difference between the distance between two adjacent first openings and the diameter of the second support portion is greater than 70 μm.

[0019] In this embodiment, after the color filter substrate and array substrate are assembled, the surface of the first support portion away from the color filter substrate, i.e., the top surface of the first support portion, contacts the array substrate. The top surface area of ​​the first support portion can be relatively small, thus reducing the static friction force generated between it and the array substrate after being compressed, making it easier to rebound and improving uneven pressing. When placed in the clip, the first support portion is compressed under long-term gravity until it is flush with the surface of the second support portion away from the color filter substrate, i.e., the top surface of the second support portion. At this time, the top surface of the second support portion also contacts the array substrate. Since the top surface area of ​​the second support portion is larger than that of the first support portion, the support strength of the main spacer can be improved, avoiding large deformation of the display panel, which helps to improve clip defects, reduce the product NG rate, and increase the product shipment rate. Therefore, the display panel in this embodiment can simultaneously reduce the risk of uneven pressing and the risk of clip defects.

[0020] An embodiment of the second aspect of this application provides a display device including the display panel of any embodiment of the first aspect. Since it has the display panel of the first aspect, it also has the beneficial effects of any embodiment of the first aspect, which will not be elaborated here.

[0021] An embodiment of the third aspect of this application provides a method for manufacturing a display panel, comprising:

[0022] Provide color filter substrates;

[0023] A main spacer and an auxiliary spacer are formed on the color filter substrate. The main spacer includes a first support portion and a second support portion. The first support portion is located on the side of the second support portion away from the color filter substrate. The surface area of ​​the side of the first support portion away from the color filter substrate is smaller than the surface area of ​​the side of the second support portion away from the color filter substrate.

[0024] An array substrate is provided, and the array substrate and the color filter substrate are aligned to obtain the display panel.

[0025] In some embodiments of this application, forming the primary spacer and the secondary spacer on the color filter substrate specifically includes:

[0026] A photoresist layer is coated on the color filter substrate;

[0027] The photoresist layer is exposed using a photomask, which includes a light-shielding area, a grayscale mask area, and a half-tone mask area. The grayscale mask area includes a light-transmitting area and a light-transmitting slit located at the edge of the light-transmitting area. The half-tone mask area includes a semi-transparent area, and the light transmittance of the semi-transparent area is less than that of the light-transmitting area.

[0028] The exposed photoresist layer is developed, wherein the photoresist corresponding to the grayscale mask area is used to form the main spacer after development, and the photoresist corresponding to the half-scale mask area is used to form the auxiliary spacer after development.

[0029] In some embodiments of this application, forming the primary spacer and the secondary spacer on the color filter substrate specifically includes:

[0030] A photoresist layer is coated on the color filter substrate;

[0031] The photoresist layer is exposed using a photomask, which includes a first light-transmitting area and a second light-transmitting area. The first light-transmitting area has a central region and an annular region surrounding the central region. The central region has a first light transmittance, and the annular region has a second light transmittance, which is less than the first light transmittance. The second light-transmitting area has a third light transmittance, which is less than the second light transmittance.

[0032] The exposed photoresist layer is developed, wherein the photoresist corresponding to the first light-transmitting area is used to form the main spacer after development, and the photoresist corresponding to the second light-transmitting area is used to form the auxiliary spacer after development.

[0033] In the display panel manufactured according to the method of this application embodiment, after the color filter substrate and the array substrate are assembled, the surface of the first support portion away from the color filter substrate, i.e., the top surface of the first support portion, contacts the array substrate. The top surface area of ​​the first support portion can be relatively small, thereby reducing the static friction force generated between it and the array substrate after being pressed, making it easier to rebound and improving the phenomenon of uneven pressing. When placed in the clip, the first support portion is compressed under the long-term gravity until it is flush with the surface of the second support portion away from the color filter substrate, i.e., the top surface of the second support portion. At this time, the top surface of the second support portion also contacts the array substrate. Since the top surface area of ​​the second support portion is larger than that of the first support portion, the support strength of the main spacer can be improved, avoiding large deformation of the display panel, which is beneficial to improving the clip defect phenomenon, reducing the product NG rate, and increasing the product shipment rate. Therefore, the display panel in this application embodiment can simultaneously reduce the risk of uneven pressing and the risk of clip defect.

[0034] Of course, implementing any product or method of the present invention does not necessarily require achieving all of the advantages described above at the same time. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings.

[0036] Figure 1 This is a cross-sectional schematic diagram of a TFT-LCD display panel in related technologies;

[0037] Figure 2a for Figure 1 The diagram shows the poor pressing results of the spacer under the first top surface size.

[0038] Figure 2b for Figure 1 The diagram shows the poor pressing results of the spacer under the second top surface size.

[0039] Figure 3 This is a top view of the display panel according to the first aspect of this application;

[0040] Figure 4 for Figure 3A magnified view of part B in the middle section.

[0041] Figure 5 for Figure 4 Sectional view at CC;

[0042] Figure 6a for Figure 5 A schematic diagram showing the relative positions of the main septum and auxiliary septum with the black matrix layer;

[0043] Figure 6b for Figure 5 A schematic diagram showing the partial distribution of the main and auxiliary spacers in the display area;

[0044] Figure 7 for Figure 5 A schematic diagram showing the relative positions of the main spacer and the auxiliary spacer with respect to the array substrate;

[0045] Figure 8 for Figure 5 A schematic diagram showing the dimensions of the main spacer is provided.

[0046] Figure 9 This is a flowchart illustrating the manufacturing process of the display panel according to Embodiment 1 of the third aspect of this application;

[0047] Figure 10 for Figure 9 The diagram shows an exposure diagram illustrating the formation of the main septum and the auxiliary septum in Embodiment 1.

[0048] Figure 11a for Figure 10 A cross-sectional schematic diagram of the grayscale mask area of ​​the mask plate shown.

[0049] Figure 11b for Figure 11a A top view of the grayscale mask area shown;

[0050] Figure 12 This is an exposure diagram illustrating the formation of the main septum and the auxiliary septum in Embodiment 2 of the third aspect of this application;

[0051] Figure 13a for Figure 12 A cross-sectional schematic diagram of the first light-transmitting area is shown;

[0052] Figure 13b for Figure 13a A top view of the first light-transmitting area shown;

[0053] Figure 1 In the middle: color filter substrate 90; array substrate 91; spacer 92; top surface 921; clip support rod 93;

[0054] Figures 3 to 13bIn the middle: display panel 10; color filter substrate 100; first substrate 110; black matrix layer 120; first opening 121; second opening 122; third opening 123; color filter 130; blue filter 131; green filter 132; red filter 133; cover layer 140; array substrate 200; scan line 201; data line 202; common electrode 203; pixel unit 204; second substrate 210; main spacer 310; First support 311; Second support 312; Auxiliary spacer 320; Mask plate 20; Light-shielding area 21; Grayscale mask area 22; Light-transmitting area 221; Light-transmitting slit 222; Half-tone mask area 23; Semi-transparent area 231; First light-transmitting area 24; Central area 241; Annular area 242; Second light-transmitting area 25; Substrate layer 26; Blue pixel area PX1; Green pixel area PX2; Red pixel area PX3; Display area AA. Detailed Implementation

[0055] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art based on this application are within the scope of protection of the present invention.

[0056] See Figure 1 , Figure 1 A cross-sectional schematic diagram of a TFT-LCD display panel in the related art is shown.

[0057] like Figure 1 As shown, in related technologies, in order to ensure the uniformity of the liquid crystal layer thickness, a spacer 92 is provided on the side of the color filter substrate 90 facing the array substrate 91 for support. The spacer 92 has a single fixed top surface 921, and the size of the top surface 921 has a significant impact on the overall pressing performance of the display panel.

[0058] See Figure 2a and Figure 2b , Figure 2a and Figure 2b It shows Figure 1 Figure showing the poor pressing results of the spacer 92 under two different top surface 921 dimensions.

[0059] in, Figure 2a and Figure 2b Corresponding to two different contact densities, the contact density is used to characterize the size of the top surface 921 of the spacer 92. The greater the contact density, the larger the size of the top surface 921 of the spacer 92. Figure 2a The corresponding contact density value is 113um 2 / mm2 , Figure 2b The corresponding contact density value is 163um 2 / mm 2 .exist Figure 2a and Figure 2b In the diagram, the horizontal axis represents the liquid crystal filling amount, and L1-L5 represent the degree of uneven pressing, where L1 represents the mildest degree of uneven pressing and L5 represents the most severe degree of uneven pressing.

[0060] contrast Figure 2a and Figure 2b It is known that, under the same liquid crystal filling amount, the higher the contact density, the higher the proportion of areas with severe uneven pressing. This means that as the contact density increases, i.e., the size of the top surface 921 of the spacer 92 increases, uneven pressing becomes more likely to occur, and the degree of uneven pressing gradually worsens. Therefore, in order to ensure the uniformity of the dark state of the display panel, the size of the top surface 921 of the spacer 92 should not be set too large.

[0061] In addition, such as Figure 1 As shown, during the production process, the display panel needs to be placed in a cassette (CST) and supported by a cassette pin (CST pin) 93. When the top surface 921 of the spacer 92 is small, the supporting strength of the spacer 92 is low. Under the influence of gravity for a long time, the display panel is prone to large plastic deformation, resulting in cassette mura.

[0062] See Table 1, which shows data on clip defects corresponding to the dimensions of the top surface 921 of the spacer 92 in the related art.

[0063] Table 1

[0064]

[0065] Comparing the first and second sets of data in Table 1, it can be seen that the TOTX and TOTY values ​​of the spacer 92 are larger in the second set compared to the first set, meaning the top surface 921 of the spacer 92 is larger. Simultaneously, the overall incidence of clamping defects in the second set is lower than in the first set, with the NG (no-conformance) rate of the second set of products decreasing by 4.84% compared to the first set. This implies that increasing the size of the top surface 921 of the spacer 92 can improve the incidence of clamping defects, reduce the NG rate, and increase the yield. Therefore, to increase product output, the size of the top surface 921 of the spacer 92 should be increased as much as possible.

[0066] In related technologies, the occurrence of uneven pressing and misalignment of the spacer 92 under different sizes is collected, and a compromise design is used to determine the design value of the top surface 921 of the spacer 92. This results in a small design margin and limited design options. Specifically, when uneven pressing occurs, the size of the top surface 921 of the spacer 92 needs to be reduced, which worsens the level of misalignment. When misalignment occurs, the size of the top surface 921 of the spacer 92 needs to be increased, which again worsens the level of uneven pressing. Therefore, the display panel used in related technologies, regardless of the size of the top surface 921 of the spacer 92, cannot simultaneously reduce the occurrence of uneven pressing and misalignment.

[0067] Therefore, an embodiment of the first aspect of this application provides a display panel 10. See also Figures 3 to 5 ,in, Figure 3 This is a top view of the display panel 10 according to Embodiment 1 of this application; Figure 4 for Figure 3 Enlarged schematic diagram of part B; Figure 5 for Figure 4 A sectional view of the CC section.

[0068] like Figures 3 to 5 As shown, the display panel 10 has a display area AA, which has multiple pixel areas of different colors. The display panel 10 includes a color filter substrate 100, an array substrate 200, and multiple main spacers 310. The array substrate 200 is disposed opposite to the color filter substrate 100. The multiple main spacers 310 are located on the side of the color filter substrate 100 facing the array substrate 200. Each main spacer 310 includes a first support portion 311 and a second support portion 312. The second support portion 312 is connected to the color filter substrate 100, and the first support portion 311 is located on the side of the second support portion 312 away from the color filter substrate 100. The surface area of ​​the side of the first support portion 311 away from the color filter substrate 100 is smaller than the surface area of ​​the side of the second support portion 312 away from the color filter substrate 100.

[0069] In this embodiment, after the color filter substrate 100 and the array substrate 200 are assembled, the surface of the first support portion 311 furthest from the color filter substrate 100, i.e., the top surface of the first support portion 311, contacts the array substrate 200. The top surface area of ​​the first support portion 311 can be relatively small, thus reducing the static friction force generated between it and the array substrate 200 under pressure, making it easier to rebound and improving uneven pressing. When placed in the clip, the first support portion 311 is compressed under the influence of gravity for a long time until it is flush with the surface of the second support portion 312 furthest from the color filter substrate 100, i.e., the top surface of the second support portion 312. At this time, the top surface of the second support portion 312 also contacts the array substrate 200. Since the top surface area of ​​the second support portion 312 is larger than that of the first support portion 311, the support strength of the main spacer 310 can be improved, preventing large deformation of the display panel 10, which helps to improve clip defects, reduce product NG rate, and increase product shipment rate. Therefore, the display panel 10 in this embodiment can simultaneously reduce the risk of uneven pressing and the risk of malfunctioning clips.

[0070] like Figure 5 As shown, in Embodiment 1, the color filter substrate 100 includes a first substrate 110, a black matrix layer 120 (BM), and a color filter 130 stacked together. The black matrix layer 120 is located on one side of the first substrate 110.

[0071] like Figure 4 and Figure 5 As shown, the black matrix layer 120 defines a plurality of first openings 121, a plurality of second openings 122, and a plurality of third openings 123 in the display area AA. A color filter 130 covers the side of the black matrix layer 120 opposite to the first substrate 110 and fills each opening.

[0072] Specifically, the color filter 130 includes a blue filter 131, a green filter 132, and a red filter 133. Each color filter only allows light of its corresponding color to pass through; for example, the blue filter 131 only allows blue light to pass through, the green filter 132 only allows green light to pass through, and the red filter 133 only allows red light to pass through. The blue filter 131 fills the first opening 121, corresponding to the blue pixel area PX1; the green filter 132 fills the second opening 122, corresponding to the green pixel area PX2; and the red filter 133 fills the third opening 123, corresponding to the red pixel area PX3. By setting the color filter 130, the display panel 10 can achieve color display. By setting the black matrix layer 120, light can pass through within the pixel area while avoiding crosstalk between different colors of light.

[0073] Furthermore, the color filter substrate 100 also includes an overcoat 140 (OC), which is located on the side of the color filter 130 facing away from the first substrate 110. A second support portion 312 of the main spacer 310 is formed on the surface of the overcoat 140 facing away from the first substrate 110, and a first support portion 311 is formed on the top surface of the second support portion 312, with the top surface area of ​​the first support portion 311 being smaller than that of the second support portion 312. After the color filter substrate 100 and the array substrate 200 are aligned, the top surface of the first support portion 311 contacts the array substrate 200.

[0074] like Figure 5 As shown, the display panel 10 also includes a plurality of auxiliary spacers 320, which are formed on the side surface of the cover layer 140 facing away from the first substrate 110. In the thickness direction of the display panel 10, the height of the auxiliary spacers 320 is less than that of the main spacers 310.

[0075] In the casement state of the display panel 10, the display panel 10 is mainly supported by the main spacer 310, while the auxiliary spacer 320 does not contact the array substrate 200. When the display panel 10 is subjected to a large external force or undergoes a pressure test, the auxiliary spacer 320 can come into contact with the array substrate 200, so that the auxiliary spacer 320 can also play a supporting role, thereby avoiding direct contact between the color filter substrate 100 and the array substrate 200, and further enhancing the supporting effect on the display panel 10.

[0076] The main spacer 310 and the auxiliary spacer 320 are arranged at alternating intervals. See details. Figure 6a and Figure 6b ,in, Figure 6a for Figure 5 A schematic diagram showing the relative positions of the main spacer 310 and the auxiliary spacer 320 with the black matrix layer 120; Figure 6b for Figure 5 A schematic diagram showing the partial distribution of the main septum 310 and the auxiliary septum 320 in the display area AA.

[0077] like Figure 6a and Figure 6b As shown, the projection of the main spacer 310 onto the black matrix layer 120 is located between two adjacent first openings 121, that is, the main spacer 310 is located between two adjacent blue pixel regions PX1; the projection of the auxiliary spacer 320 onto the black matrix layer 120 is located between two adjacent first openings 121 or between two adjacent third openings 123, that is, the auxiliary spacer 320 is located between two adjacent blue pixel regions PX1 or between two adjacent red pixel regions PX3.

[0078] Considering that the transmittance of the green filter 132 in the display panel 10 is greater than that of the blue filter 131 and the red filter 133, in order to improve the overall transmittance of the display panel 10, the area of ​​the second opening 122 corresponding to the green filter 132 may be larger. This means that the distance between two adjacent second openings 122 in the black matrix layer 120 may be smaller. If the main spacer 310 or the auxiliary spacer 320 is located between two adjacent second openings 122, it will cause the main spacer 310 or the auxiliary spacer 320 to easily slide into the pixel area after being pressed, thereby causing light leakage. Therefore, in this embodiment, by making the projection of the spacer in the black matrix layer 120 between two adjacent first openings 121, and the projection of the auxiliary spacer 320 in the black matrix layer 120 between two adjacent first openings 121 or between two adjacent third openings 123, it is beneficial to improve the light leakage phenomenon of the display panel 10 and reduce the risk of bright spot defects.

[0079] In one specific embodiment, a main spacer 310 or an auxiliary spacer 320 is provided between every two adjacent first openings 121, and an auxiliary spacer 320 is provided between every two adjacent third openings 123, and the number of auxiliary spacers 320 is greater than the number of main spacers 310.

[0080] In a specific embodiment, such as Figure 6b As shown, the ratio of the number of main spacers 310 to the total number of pixel areas is 1:36, and the ratio of the number of auxiliary spacers 320 to the total number of pixel areas is 23:36. This satisfies the support requirements of the display panel 10 while reducing manufacturing costs.

[0081] In other embodiments of this application, the main spacer 310 and the auxiliary spacer 320 may be arranged according to the design size of each opening of the black matrix layer 120. The main spacer 310 or the auxiliary spacer 320 may also be located between two adjacent second openings 122. This application does not limit this arrangement.

[0082] Further, see Figure 7 , Figure 7 for Figure 5 The diagram shows the relative positions of the main spacer 310 and the auxiliary spacer 320 with the array substrate 200.

[0083] like Figure 5 and Figure 7 As shown in the embodiment of this application, the array substrate 200 includes a second substrate 210. A plurality of scan lines 201 and a plurality of data lines 202 are formed on one side of the second substrate 210. The scan lines 201 and data lines 202 intersect perpendicularly to define a plurality of pixel units 204. Each pixel unit 204 corresponds to a pixel region, and each pixel unit 204 is provided with a pixel electrode.

[0084] The array substrate 200 also includes a plurality of uniformly distributed thin-film transistors, each connected to a pixel electrode. Each thin-film transistor includes a gate, a source, and a drain. Each data line 202 is connected to the source of the thin-film transistor in the same column, each scan line 201 is connected to the gate of the thin-film transistor in the same row, and the pixel electrode is connected to the drain of the corresponding thin-film transistor. By applying a scan signal to the scan line 201, the thin-film transistor connected to the same scan line 201 is turned on, thereby charging the pixel electrode through the turned-on thin-film transistors using the data voltage applied to the data line 202.

[0085] like Figure 5 and 7 As shown, the projections of the main spacer 310 and the auxiliary spacer 320 onto the array substrate 200 lie within the range of the scan line 201. Considering that the width of the scan line 201 is greater than that of the data line 202, the projections of the main spacer 310 and the auxiliary spacer 320 onto the array substrate 200 are aligned with the scan line 201. This provides a larger sliding range for the main spacer 310 and the auxiliary spacer 320, preventing them from entering the pixel area after being pressed and slid.

[0086] Furthermore, the projections of the main spacer 310 and the auxiliary spacer 320 onto the array substrate 200 are located within the scan line 201 and do not overlap with the thin-film transistor. In other words, the positions of the main spacer 310 and the auxiliary spacer 320 on the array substrate 200 correspond to the area of ​​the scan line 201 excluding the thin-film transistor.

[0087] Considering that in a thin-film transistor (TFT), the gate and scan line 201 are disposed on the same layer, and the source and drain are located on the side of the gate closer to the color filter substrate 100, the source and drain portions of the TFT will protrude from the scan line 201. If the main spacer 310 is placed on the TFT after the cell assembly, it is easy for the main spacer 310 to become suspended after being pressed and slipped, resulting in a significant reduction in the support reliability of the display panel 10. Therefore, in this embodiment, by placing the main spacer 310 on the array substrate 200 in the area of ​​the scan line 201 other than the TFT, the support stability of the main spacer 310 can be improved.

[0088] Furthermore, because the source and drain portions of the thin-film transistor protrude from the scan line 201, the distance between the thin-film transistor and the color filter substrate 100 is relatively small. If the position of the auxiliary spacer 320 on the array substrate 200 corresponds to the thin-film transistor, the height of the auxiliary spacer 320 is relatively short due to spatial limitations, resulting in poor uniformity of the auxiliary spacer 320 during manufacturing.

[0089] Therefore, in this embodiment, by setting the position of the auxiliary spacer 320 on the array substrate 200 in the area of ​​the scan line 201 other than the thin film transistor, the position of the auxiliary spacer 320 on the array substrate 200 can be located at a lower position, which is beneficial to increase the height of the auxiliary spacer 320 and improve the uniformity of the fabrication of the auxiliary spacer 320.

[0090] like Figure 5 As shown in this embodiment, the array substrate 200 further includes a common electrode 203, which is used to provide a reference voltage for the thin-film transistor. In this embodiment, the common electrode 203 can be located on the side of the scan line 201 near the second substrate 210. The common electrode 203 and the scan line 201 can be formed in one patterning process after two film depositions, thereby reducing the use of the mask 20 and simplifying the process steps.

[0091] In other embodiments of this application, the common electrode 203 may also be disposed on the same layer as the scan line 201, and this application does not impose any restrictions on this.

[0092] In the embodiments of this application, such as Figure 5 As shown, the first support portion 311 and the second support portion 312 are cylindrical structures extending along the thickness direction of the display panel 10. The cross-sections of the first support portion 311 and the second support portion 312 are circular. The end of the first support portion 311 away from the second support portion 312 can be referred to as the top of the main spacer 310, and the end of the second support portion 312 away from the first support portion 311 can be referred to as the bottom of the main spacer 310. The connection between the first support portion 311 and the second support portion 312 can be referred to as the shoulder of the main spacer 310. According to the inventor's experimental verification, compared with other shapes, by setting the first support portion 311 and the second support portion 312 as cylindrical structures, the main spacer 310 can have a larger support area.

[0093] The design principles of the main spacer 310 in the embodiments of this application are described below.

[0094] See Figure 8 , Figure 8 This is a schematic diagram of the dimensions of the main spacer 310 shown in Figure 5.

[0095] like Figure 8 As shown in the embodiment of this application, the height of the first support 311 in the thickness direction of the display panel 10 is H1, and the total height of the main spacer 310 in the thickness direction of the display panel 10 is H3, where H1 > C × H3; and C is the center compression ratio of the main spacer 310.

[0096] Specifically, for the display panel 10, the amount of liquid crystal directly affects the display performance, and a safe range of liquid crystal volume is called the liquid crystal margin (LC Margin). Currently, in TFT-LCD display technology, the height of the main spacer 310 is the primary factor affecting the liquid crystal margin, and the deformation of the main spacer 310 under external force also affects the liquid crystal margin. To ensure the liquid crystal margin, the center compression ratio C of the main spacer 310 is generally specified to be 13.45%. By ensuring that H1 > 0.1345 × H3, it is possible to prevent the shoulder of the main spacer 310 from contacting the array substrate 200 after cell alignment, thus avoiding uneven pressing.

[0097] In other embodiments of this application, the central compression ratio C of the primary spacer 310 may also be other values, and this application does not limit this.

[0098] Furthermore, H1 < C × H3 + 0.02 × CG, where CG is the thickness of the display panel 10.

[0099] Considering that when there is a 2% difference in the thickness of the liquid crystal cell (Cell Gap, or CG) at two locations, which is the thickness of the display panel 10, a noticeable difference in brightness can be observed by the naked eye, resulting in display defects, the risk of display defects can be reduced by controlling the height difference between the highest and lowest positions after the cell to within 2% of the cell thickness, i.e., H1-C×H3<0.02×CG.

[0100] From H1-C×H3<0.02×CG, we can deduce that H1<C×H3+0.02CG. Therefore, in Example 1, C×H3

[0101] In Embodiment 1, the diameter of the first support portion 311 is L1. The diameter of the first support portion 311 is greater than or equal to 10 μm and less than or equal to 14 μm, that is, 10 μm ≤ L1 ≤ 4 μm.

[0102] The diameter of the first support portion 311 is related to the planar dimensions of the display panel 10. Optionally, when the display panel 10 is applied to small-sized products, such as products with a display panel size less than 43 inches, like mobile phones and tablets, the diameter of the first support portion 311 is 10µm. When the display panel 10 is applied to large-sized products, such as products with a display panel size greater than 43 inches, like televisions, the diameter of the first support portion 311 is 14µm. This ensures sufficient support strength for the display panel 10 behind the box while effectively reducing the risk of improper pressure on the display panel 10.

[0103] Furthermore, such as Figure 8 ​As shown, the diameter of the second support portion 312 is L2, where L2 > L1. Figure 6a As shown, the distance between two adjacent first openings 121 is L3.

[0104] In this embodiment, the difference between the distance L3 between two adjacent first openings 121 and the diameter L2 of the second support portion 312 is greater than 40 μm, i.e., L3 - L2 > 40 μm; or, the difference between the distance L3 between two adjacent first openings 121 and the diameter L2 of the second support portion 312 is greater than 70 μm, i.e., L3 - L2 > 70 μm. Optionally, when the display panel 10 is applied to a small-sized product, the difference between the distance L3 between two adjacent first openings 121 and the diameter L2 of the second support portion 312 is greater than 40 μm. When the display panel 10 is applied to a large-sized product, the difference between the distance L3 between two adjacent first openings 121 and the diameter L2 of the second support portion 312 is greater than 70 μm. For reference, a large-sized product refers to a display panel 10 with a size greater than 43 inches, such as a television; a small-sized product refers to a display panel 10 with a size less than 43 inches, such as a mobile phone or tablet. This reduces the incidence of clip failure and prevents bright spot defects.

[0105] It should be noted that the above parameters are all design parameters. In the actual manufacturing process, the final product parameters may deviate to some extent due to the influence of the manufacturing process.

[0106] In this embodiment, the auxiliary spacer 320 is also a cylindrical structure. The height of the auxiliary spacer 320 is less than the height of the main spacer 310, and its diameter is greater than that of the main spacer 310. In practical applications, the height and diameter of the auxiliary spacer 320 can be designed according to the support strength.

[0107] In other embodiments of this application, the main spacer 310 and the auxiliary spacer 320 may also be other structures, such as cubic pillars with rectangular interfaces, etc., and this application does not limit them.

[0108] An embodiment of the second aspect of this application provides a display device, including the display panel 10 of any embodiment of the first aspect.

[0109] In this embodiment, the display device includes a display panel 10, which includes a color filter substrate 100 and an array substrate 200 disposed opposite to each other. A plurality of main spacers 310 are provided between the color filter substrate 100 and the array substrate 200. Each main spacer 310 includes a first support portion 311 and a second support portion 312. The first support portion 311 is located on the side of the second support portion 312 away from the color filter substrate 100, and the surface area of ​​the side of the first support portion 311 away from the color filter substrate 100 is smaller than the surface area of ​​the side of the second support portion 312 away from the color filter substrate 100. After the color filter substrate 100 and the array substrate 200 are aligned, the surface of the first support portion 311 away from the color filter substrate 100, i.e., the top surface of the first support portion 311, contacts the array substrate 200. Since the top surface area of ​​the first support portion 311 can be relatively small, the static friction force generated between it and the array substrate 200 after pressure is small, making it easier to rebound and improving uneven pressing. When placed in the clip, the first support 311 is compressed under the influence of gravity over a long period of time until it is flush with the top surface of the second support 312, which is the side of the second support 312 away from the color filter substrate 100. At this time, the top surface of the second support 312 also contacts the array substrate 200. Since the top surface area of ​​the second support 312 is larger than that of the first support 311, the support strength of the main spacer 310 can be improved, avoiding large deformation of the display panel 10. This helps to improve the clip defect phenomenon, reduce the product NG rate, and increase the product shipment rate. Therefore, the display panel 10 in this embodiment can simultaneously reduce the risk of uneven pressing and the risk of clip defect.

[0110] See Figure 9 , Figure 9 This is a flowchart illustrating the manufacturing process of the display panel 10 according to Embodiment 1 of the third aspect of this application.

[0111] like Figure 9 As shown, Embodiment 1 of the third aspect of this application provides a method for manufacturing a display panel 10, comprising:

[0112] S1. Provide color filter substrate 100;

[0113] S2. A main spacer 310 and an auxiliary spacer 320 are formed on the color filter substrate 100. The main spacer 310 includes a first support portion 311 and a second support portion 312. The first support portion 311 is located on the side of the second support portion 312 that is away from the color filter substrate 100. The surface area of ​​the side of the first support portion 311 that is away from the color filter substrate 100 is smaller than the surface area of ​​the side of the second support portion 312 that is away from the color filter substrate 100.

[0114] S3. Provide an array substrate 200, and assemble the array substrate 200 with the color filter substrate 100 to obtain a display panel 10.

[0115] In the display panel 10 manufactured according to the manufacturing method of the embodiment of this application, after the color filter substrate 100 and the array substrate 200 are assembled, the surface of the first support portion 311 away from the color filter substrate 100, that is, the top surface of the first support portion 311, contacts the array substrate 200. The top surface area of ​​the first support portion 311 can be small, thereby reducing the static friction force generated between it and the array substrate 200 after being pressed, making it easy to rebound and improving the phenomenon of uneven pressing. When placed in the clip, the first support 311 is compressed under the influence of gravity over a long period of time until it is flush with the top surface of the second support 312, which is the side of the second support 312 away from the color filter substrate 100. At this time, the top surface of the second support 312 also contacts the array substrate 200. Since the top surface area of ​​the second support 312 is larger than that of the first support 311, the support strength of the main spacer 310 can be improved, avoiding large deformation of the display panel 10. This helps to improve the clip defect phenomenon, reduce the product NG rate, and increase the product shipment rate. Therefore, the display panel 10 in this embodiment can simultaneously reduce the risk of uneven pressing and the risk of clip defect.

[0116] Further, see Figures 10 to 11b ,in Figure 10 for Figure 9 An exposure diagram showing the formation of the main septum 310 and the auxiliary septum 320 in Embodiment 1; Figure 11a for Figure 10 A cross-sectional schematic diagram of the grayscale mask region 22 of the mask plate 20 shown; Figure 11b for Figure 11a The top view of the grayscale mask area 22 shown.

[0117] The formation of the main spacer 310 and the auxiliary spacer 320 on the color filter substrate 100 specifically includes:

[0118] A photoresist layer is coated on the color filter substrate 100;

[0119] The photoresist layer is exposed using a photomask 20; for example... Figures 10 to 11b As shown, the mask plate 20 includes a light-blocking area 21, a grayscale mask area 22 (Gray Tone Mask, abbreviated as GTM), and a half-tone mask area (Half Tone Mask, abbreviated as HTM) 23; the grayscale mask area 22 includes a central light-transmitting area 221 and a light-transmitting slit 222 located at the edge of the central light-transmitting area 221; the half-tone mask area 23 includes a semi-transparent area 231, the transmittance of the semi-transparent area 231 is less than that of the central light-transmitting area 221;

[0120] The exposed photoresist layer is developed, wherein the photoresist corresponding to the grayscale mask region 22 is used to form the main spacer 310 after development, and the photoresist corresponding to the half-tone mask region 23 is used to form the auxiliary spacer 320 after development.

[0121] In this embodiment, the mask 20 may include a substrate 26; a light-shielding area 21, a grayscale mask area 22, and a half-tone mask area 23 are located on one side of the substrate 26. In the grayscale mask area 22, the transmittance of the central light-transmitting area 221 is 100%, and the transmittance of the light-transmitting slit 222 can also be 100%. By setting the light-transmitting slit 222 at the edge of the central light-transmitting area 221, the light-slimming effect of the light-transmitting slit 222 can be used to reduce the exposure intensity at the edge. This allows the photoresist corresponding to the grayscale mask area 22 to form a first support portion 311 with a smaller cross-section and a second support portion 312 with a larger cross-section after a single exposure and development, which helps to simplify the process steps.

[0122] In other embodiments of this application, the light transmittance of the light-transmitting slit 222 may also be less than that of the central light-transmitting area 221, and this application does not impose any restrictions on this.

[0123] Furthermore, the transmittance of the semi-transparent region 231 is less than that of the transparent region 221. Therefore, after exposure and development, the photoresist corresponding to the semi-tone mask region 23 can form a low-height spacer 320.

[0124] In this embodiment, by using the photoresist layer to expose the photomask 20, the main spacer 310 and the auxiliary spacer 320 can be formed simultaneously after one development, which helps to further simplify the process steps and reduce the manufacturing cost.

[0125] It should be noted that the light transmittance of the central light-transmitting area 221, the light-transmitting slit 222, and the semi-light-transmitting area 231 can be set according to the actual size of the main spacer 310 and the auxiliary spacer 320, and this application does not impose any restrictions on this.

[0126] In the embodiments of this application, the number of light-transmitting slits 222 can be set according to the specific dimensions of the first support portion 311 and the second support portion 312, and this application does not limit this.

[0127] See Figures 12 to 13b ,in Figure 12 This is an exposure diagram illustrating the formation of the main septum 310 and the auxiliary septum 320 in Embodiment 2 of the third aspect of this application; Figure 13a for Figure 12 A cross-sectional schematic diagram of the first light-transmitting area 24 of the mask plate 20 shown; Figure 13b for Figure 13a The top view of the first light-transmitting area 24 shown.

[0128] In Embodiment 2 of this application, unlike Embodiment 1, the formation of the main spacer 310 and the auxiliary spacer 320 on the color filter substrate 100 specifically includes:

[0129] A photoresist layer is coated on the color filter substrate 100;

[0130] The photoresist layer is exposed using a photomask 20; for example... Figures 12 to 13b As shown, the photomask 20 includes a first light-transmitting area 24 and a second light-transmitting area 25. The first light-transmitting area 24 has a central region 241 and an annular region 242 surrounding the central region 241. The central region 241 has a first transmittance, and the annular region 242 has a second transmittance, which is less than the first transmittance. The second light-transmitting area 25 has a third transmittance, which is less than the second transmittance.

[0131] The exposed photoresist layer is developed, wherein the photoresist corresponding to the first light-transmitting area 24 is used to form the main spacer 310 after development, and the photoresist corresponding to the second light-transmitting area 25 is used to form the auxiliary spacer 320 after development.

[0132] In Example 2, the mask 20 used is a multi-tone mask (MTM). The mask 20 has a first transparent region 24, which includes a central region 241 and an annular region 242. The central region 241 has 100% transmittance, while the annular region 242 has less transmittance than the central region 241. Therefore, after a single exposure and development, a first support portion 311 and a second support portion 312 with different cross-sectional dimensions can be formed, which simplifies the process and reduces manufacturing costs.

[0133] The mask plate 20 also has a second light-transmitting area 25, the light transmittance of the second light-transmitting area 25 is less than that of the annular area 242, so that while forming the main spacer 310, an auxiliary spacer 320 with a height lower than the second support 312 can be formed.

[0134] It should be noted that the light transmittance of each light-transmitting zone can be set according to the actual size of the main spacer 310 and the auxiliary spacer 320, and this application does not impose any restrictions on this.

[0135] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0136] The various embodiments in this specification are described in a related manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, the system embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions of the method embodiments.

[0137] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. A display panel having a display area, the display area having a plurality of different color pixel regions; characterized in that, The display panel comprises: a color film substrate; an array substrate disposed opposite to the color film substrate; a plurality of main spacers located on a side of the color film substrate facing the array substrate, each of the main spacers comprising a first support portion and a second support portion, the second support portion being connected to the color film substrate, and the first support portion being located on a side of the second support portion away from the color film substrate; a surface area of a side of the first support portion away from the color film substrate being smaller than a surface area of a side of the second support portion away from the color film substrate; H1>C*H3; wherein H1 is a height value of the first support portion in a thickness direction of the display panel, C is a center compression rate of the main spacer, and H3 is a total height value of the main spacer in the thickness direction of the display panel; H1 2. The display panel of claim 1, wherein, The color film substrate comprises a black matrix layer, the black matrix layer defining a plurality of first openings, a plurality of second openings and a plurality of third openings in the display area, the first openings corresponding to blue pixel regions, the second openings corresponding to green pixel regions, and the third openings corresponding to red pixel regions; A projection of the main spacer on the black matrix layer is located between two adjacent first openings.

3. The display panel of claim 1, wherein, The array substrate comprises a plurality of scan lines and a plurality of data lines, the scan lines and the data lines perpendicularly intersecting to define a plurality of pixel units, the pixel units corresponding one-to-one to the pixel regions; A projection of the main spacer on the array substrate is located within a range of the scan lines.

4. The display panel of claim 2 or 3, wherein, The display panel further comprises a plurality of auxiliary spacers; the plurality of auxiliary spacers are located on a side of the color film substrate facing the array substrate, and a height of the auxiliary spacers in a thickness direction of the display panel is smaller than that of the main spacers.

5. The display panel of claim 4, wherein, A projection of the auxiliary spacer on the black matrix layer is located between two adjacent first openings or between two adjacent third openings.

6. The display panel of claim 5, wherein, Each of two adjacent first openings is provided with the main spacer or the auxiliary spacer, each of two adjacent third openings is provided with the auxiliary spacer, and a number of the auxiliary spacers is greater than that of the main spacers.

7. The display panel of claim 4, wherein, The array substrate further comprises a plurality of thin film transistors uniformly distributed, the thin film transistors corresponding one-to-one to the pixel units; The projections of the main spacers and the auxiliary spacers on the array substrate are located within the range of the scan lines and do not overlap the thin film transistors.

8. The display panel of claim 2, wherein, The first support portion is in a cylindrical structure, the first support portion extending in the thickness direction of the display panel, and a diameter of the first support portion is greater than or equal to 10 um and less than or equal to 14 um.

9. The display panel of claim 2, wherein, The second support part is a cylindrical structure, the second support part extends along the thickness direction of the display panel, the diameter of the second support part is greater than the first support part, the connecting surface of the second support part and the first support part forms a shoulder of the main spacer, the difference between the interval of two adjacent first openings and the diameter of the second support part is greater than 40 um, or the difference between the interval of two adjacent first openings and the diameter of the second support part is greater than 70 um.

10. A display device, characterized by comprising: The display panel of any one of claims 1-9.

11. A manufacturing method of a display panel, comprising: A display panel of any one of claims 1-9 is prepared, comprising: providing a color film substrate; forming a main spacer and an auxiliary spacer on the color film substrate, the main spacer comprises a first support part and a second support part, the first support part is located on the side of the second support part away from the color film substrate; the surface area of the side of the first support part away from the color film substrate is less than the surface area of the side of the second support part away from the color film substrate; providing an array substrate, and aligning the array substrate with the color film substrate to obtain the display panel.

12. The method of manufacturing according to claim 11, wherein, The forming a main spacer and an auxiliary spacer on the color film substrate specifically comprises: coating a photoresist layer on the color film substrate; exposing the photoresist layer using a mask plate, the mask plate comprises an opaque area, a gray-tone mask area and a half-tone mask area; the gray-tone mask area comprises a light-transmitting area and a light-transmitting slit located at the edge of the light-transmitting area; the half-tone mask area comprises a semi-light-transmitting area, the light-transmitting rate of the semi-light-transmitting area is less than that of the light-transmitting area; developing the exposed photoresist layer, wherein the photoresist corresponding to the gray-tone mask area is used to form the main spacer after development, and the photoresist corresponding to the half-tone mask area is used to form the auxiliary spacer after development.

13. The method of manufacturing according to claim 11, wherein, The forming a main spacer and an auxiliary spacer on the color film substrate specifically comprises: coating a photoresist layer on the color film substrate; exposing the photoresist layer using a mask plate, the mask plate comprises a first light-transmitting area and a second light-transmitting area, the first light-transmitting area has a center area and an annular area surrounding the center area, the center area has a first light-transmitting rate, the annular area has a second light-transmitting rate, the second light-transmitting rate is less than the first light-transmitting rate; the second light-transmitting area has a third light-transmitting rate, the third light-transmitting rate is less than the second light-transmitting rate; developing the exposed photoresist layer, wherein the photoresist corresponding to the first light-transmitting area is used to form the main spacer after development, and the photoresist corresponding to the second light-transmitting area is used to form the auxiliary spacer after development.

Images