Array Substrate Protrusions Prevent Ag Ion Migration Bright Spots
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Solution Overview
Problem
Reflection type Liquid Crystal Displays (RLCD) suffer from defects such as bright spots due to conductive connections between adjacent reflective portions caused by inconsistent etching rates and Ag ion migration, especially under high temperature and humidity conditions.
Innovation Solution
The array substrate design includes a first protruding portion in the gap between reflective portions, which increases the migration path for Ag ions and enhances etching efficiency, preventing conductive connections and bright spots by ensuring a wider gap and smoother material removal during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reflective layer group with adjacent reflective portions is used, then the display can achieve reflection type liquid crystal display functionality, but conductive connections between adjacent reflective portions occur due to inconsistent etching rates and Ag ion migration, causing bright spots
Solution Approach 1:
The insulating layer group is divided into multiple protruding portions that extend into the gaps between adjacent reflective portions. These protruding portions act as physical barriers that segment the migration path of Ag ions, preventing them from forming conductive connections between adjacent reflective portions. This segmentation approach directly addresses the bright spot defect by creating isolated regions that prevent electrical leakage.
Solution Approach 2:
The solution introduces a vertical dimension by forming protruding portions that extend upward from the insulating layer group into the gap between reflective portions. This three-dimensional structure creates a physical barrier in the vertical direction, increasing the migration path length for Ag ions and preventing lateral conduction between adjacent reflective portions, thereby eliminating bright spots.
2Area of moving object
If the gap between adjacent reflective portions is reduced to improve display density, then more reflective portions can be packed in a smaller area, but Ag ion migration and conductive connections become more likely, increasing bright spots
Solution Approach 1:
The protruding portions of the insulating layer group serve as intermediary structures that fill the gaps between adjacent reflective portions. These intermediaries act as physical barriers that mediate between the closely spaced reflective portions, preventing direct contact and Ag ion migration while allowing the gap to remain small for high display density. The protruding portions create a controlled insulation barrier that maintains both density and reliability.
3Productivity
If etching processes are optimized to remove material completely, then manufacturing efficiency improves, but inconsistent etching rates cause residue formation that leads to conductive connections and bright spots
Solution Approach 1:
The protruding portions are formed as part of the insulating layer group structure before the reflective layer group is deposited. This preliminary formation of the protruding portions creates pre-defined insulation barriers that guide subsequent etching processes. The pre-formed protruding portions ensure consistent etching depth and prevent residue accumulation in the gaps between reflective portions, leading to uniform etching results that prevent bright spots while maintaining manufacturing efficiency.
Data Source
AI summary
An array substrate, a display panel, and a display device are provided. The array substrate includes: a first base substrate, an insulating layer group and a reflective layer group. The insulating layer group is arranged at a side of the first base substrate, and a surface of the insulating layer group away from the first base substrate is provided with a first protruding portion. The reflective layer group is arranged at a side of the insulating layer group away from the first base substrate. The reflective layer group includes a plurality of reflective portions, a first gap is provided between two adjacent reflective portions, and the first protruding portion is arranged in the first gap.