Array Substrate Filling Pattern for Display Panel Alignment Film Protection
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Solution Overview
Problem
The existing display panel technologies face defects such as light leakage, insufficient liquid crystal, and impact issues due to the movement of column spacers and the shape of contact holes, which affect the alignment film and cell gap, leading to quality deviations and increased failure rates.
Innovation Solution
A filling pattern is introduced on the array substrate to fill contact holes and support column spacers, maintaining uniform cell gaps and reducing liquid crystal volume, while ensuring the alignment film's integrity by protruding from the protective layer and being made of the same material as the column spacer to mitigate friction damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If column spacers are used to maintain cell gap, then cell gap is maintained, but column spacers may move causing light leakage and alignment film damage
Solution Approach 1:
The support structure is segmented into multiple column spacers distributed across the substrate. Each column spacer independently maintains the cell gap in its local region, preventing any single point of failure from compromising the entire structure. This segmentation allows the system to maintain overall cell gap uniformity while isolating potential movement issues to individual spacers.
Solution Approach 2:
The column spacers are pre-positioned and fixed onto the array substrate before the color filter substrate is attached. This preliminary action ensures that the cell gap is established and maintained from the beginning of the assembly process, preventing later adjustments that could cause alignment film damage. The spacers are prepared in advance to withstand the assembly process without moving.
2Reliability
If contact holes are formed for pixel electrode connection, then electrical connection is achieved, but contact hole shape causes liquid crystal volume deviation
Solution Approach 1:
The invention applies different structural characteristics to different regions of the contact holes. The lower portion of each contact hole maintains the original shape for electrical connection, while the upper portion is filled with a filling pattern that has optimized geometry for liquid crystal volume control. This local differentiation allows the contact hole to simultaneously achieve reliable electrical connection and precise liquid crystal volume uniformity.
Solution Approach 2:
The filling pattern modifies the contact hole's geometric parameters, particularly the upper opening area and side wall angles. By changing these parameters through the filling process, the liquid crystal volume above the contact hole is controlled and uniformized, compensating for variations introduced by the original contact hole formation process while preserving the electrical connection function.
3Manufacturing precision
If filling pattern is added to fill contact holes, then liquid crystal volume is optimized, but device complexity increases
Solution Approach 1:
The filling pattern serves multiple functions simultaneously: it optimizes liquid crystal volume by controlling the cavity geometry, provides additional mechanical support to prevent column spacer movement, and maintains electrical insulation between adjacent contact holes. This multi-functionality reduces the need for separate structures, thereby limiting the increase in device complexity while achieving precise liquid crystal volume uniformity.
Solution Approach 2:
The filling pattern merges several structural requirements into a single element. It combines the liquid crystal volume control function with the mechanical support function and the electrical insulation function. By merging these functions into one integrated structure, the overall device complexity is minimized while still achieving the desired liquid crystal volume uniformity.
4Reliability
If column spacers are made of same material as filling pattern, then friction damage is reduced, but material selection becomes more constrained
Solution Approach 1:
The column spacers and filling pattern are made of the same material, creating a homogeneous structure with uniform mechanical properties. This homogeneity ensures that friction forces between these components are minimized and uniformly distributed, reducing the risk of alignment film damage. The consistent material composition throughout these elements provides predictable friction characteristics that protect the alignment film during device operation and assembly.
Data Source
AI summary
Disclosed herein is a display panel in which a space between a color filter substrate and an array substrate is filled with liquid crystals. The cell gap between the color filter substrate and the array substrate is maintained by a column spacer and a filling pattern with which a contact hole is filled. Accordingly, it is possible to stress damage to an alignment film by the movement of the column spacer even if the display panel is deformed by external force. In addition, the contact hole is filled with the filling pattern, thereby suppressing overcoming the problem of insufficient or excessive amount of liquid crystals.