Array Substrate Flow Guiding Structure for Display Panel Mura Reduction
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Solution Overview
Problem
Existing liquid crystal display panels face issues with poor fluidity of alignment layer forming solution due to parallel and uniformly designed photo spaced retaining walls, leading to residue accumulation and uneven cell gaps, particularly at the periphery, resulting in 'mura' and brightness inconsistencies.
Innovation Solution
An array substrate with a retaining wall structure and a flow guiding structure having a different height than the retaining wall, featuring a groove and alternate arrangements of dummy photo spaced walls and openings, which guides the alignment layer forming solution back to the effective display area, preventing accumulation and ensuring uniform cell gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If parallel and uniformly designed photo spaced retaining walls are used, then the structure is simple and easy to manufacture, but the alignment layer forming solution has poor fluidity causing residue accumulation
Solution Approach 1:
The patent applies asymmetry by designing the flow guiding structure with varying heights (first height different from second height) rather than using uniform parallel retaining walls. This asymmetric design creates different flow resistance zones that guide the alignment layer forming solution to flow smoothly without accumulation, resolving the contradiction between simple manufacturing and manufacturing precision.
Solution Approach 2:
The flow guiding structure is segmented into multiple portions with different heights arranged in sequence. This segmentation allows the structure to control fluid flow at different stages, preventing residue accumulation while maintaining manufacturability through modular design elements.
2Reliability
If photo spaced retaining walls are used to prevent alignment layer forming solution overflow, then the alignment layer is contained, but the solution accumulates at the walls causing cell gap variation
Solution Approach 1:
The flow guiding structure acts as an intermediary between the retaining walls and the alignment layer forming solution. It mediates the flow by providing a graduated height structure that guides the solution back into the effective display area, preventing both overflow and accumulation, thus maintaining reliability and manufacturing precision.
Solution Approach 2:
The patent introduces a height dimension variation in the flow guiding structure, creating a three-dimensional graduated structure rather than a flat two-dimensional barrier. This dimensional change allows the structure to actively guide flow dynamics, preventing accumulation while maintaining containment reliability.
3Manufacturing precision
If the alignment layer forming solution is guided back to the effective display area, then fluidity is improved, but the structure becomes more complex
Solution Approach 1:
The flow guiding structure is designed to perform multiple functions: it acts as a barrier to prevent overflow, a guide to direct flow back to the effective display area, and a controller to maintain uniform cell gap. This multi-functionality reduces the need for separate structures, managing complexity while achieving manufacturing precision.
Solution Approach 2:
The patent merges the functions of retaining walls and flow guidance into a single integrated flow guiding structure. By combining these functions, the structure manages alignment layer forming solution effectively without requiring separate components, balancing complexity reduction with manufacturing precision improvement.
4Device complexity
If uniform height retaining walls are used, then the structure is simple, but brightness uniformity deteriorates due to residue accumulation
Solution Approach 1:
The asymmetric height design of the flow guiding structure prevents residue accumulation that causes brightness non-uniformity. By creating varying flow resistance zones, the structure ensures uniform solution distribution, improving brightness uniformity without requiring overly complex multi-component systems.
Solution Approach 2:
The patent applies local quality by having different portions of the flow guiding structure with different heights tailored to specific flow control needs. This localized variation in structure quality ensures uniform brightness across the display by preventing accumulation in critical areas, while maintaining overall structural simplicity.
Data Source
AI summary
A display panel comprises an array substrate, an opposing substrate, a liquid crystal layer and a sealing member. An array substrate comprises a substrate, a switch array structure formed on the substrate, a retaining wall structure disposed on the peripheral region of the substrate and substantially surrounding the switch array structure, and a flow guiding structure disposed on an area surrounding the peripheral region between the switch array structure and the retaining wall structure and having a height different from a height of the retaining wall structure. The opposing substrate is disposed opposing to the array substrate, and the liquid crystal layer is interposed between the array substrate and the opposing substrate, and the sealing member is disposed on the array substrate corresponding to the location surrounding the periphery of the liquid crystal layer and seals the array substrate and the opposing substrate.