Array Substrate Stepped Via Groove Alignment
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Solution Overview
Problem
In liquid crystal display panels, uneven columnar spacers on the color filter substrate lead to misalignment and deformation, causing light leakage and uneven cell thickness, which affects display quality, especially when the panels are used vertically or subjected to external forces.
Innovation Solution
A stepped structure is formed between the common electrode line and the base within via holes on the array substrate, creating a groove that accommodates columnar spacers, preventing sliding and misalignment and allowing for uniform cell thickness and deformation accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If transparent conductive oxide films are used as hole injection type electrodes, then visibility is improved, but manufacturing complexity increases due to multiple film deposition processes
Solution Approach 1:
The patent extracts and removes the transparent conductive oxide film from the electrode structure, replacing it with a low-work-function metal film that provides both conductivity and hole injection functionality in a single layer, thereby simplifying the manufacturing process while maintaining visibility
Solution Approach 2:
The low-work-function metal film serves multiple functions simultaneously: it acts as both the conductive electrode and the hole injection layer, eliminating the need for separate transparent conductive oxide films and simplifying the overall device structure
2Ease of manufacture
If electron injection type electrodes are used, then manufacturing process is simplified, but image quality deteriorates due to electron leakage and dark spots
Solution Approach 1:
The patent inverts the electrode type from electron injection type to hole injection type by using low-work-function metal films, which prevents electron leakage and dark spots while maintaining manufacturing simplicity through single-layer deposition processes
3Device complexity
If conventional electrode structures are used, then device structure is simple, but display uniformity deteriorates due to visible electrodes and non-uniform light emission
Solution Approach 1:
The patent applies local quality by using low-work-function metal films with specific material properties (work function 4.0-5.0 eV) that are strategically positioned at the electrode interface to enable efficient hole injection and eliminate visible electrode effects, achieving uniform display characteristics
Solution Approach 2:
The patent employs composite material structures combining low-work-function metal films with organic light-emitting materials, where the metal film's specific electrical and optical properties complement the organic materials to achieve both structural simplicity and display uniformity
4Reliability
If multiple thin films are deposited to form electrodes, then electrode functionality is enhanced, but production cost increases due to multiple vacuum deposition processes
Solution Approach 1:
The patent removes the expensive transparent conductive oxide film deposition process by replacing it with a single low-work-function metal film deposition, reducing the number of vacuum deposition steps from multiple to one, thereby lowering production costs while maintaining electrode functionality
Solution Approach 2:
The patent uses low-work-function metal films that can be deposited in a single process step, replacing expensive multi-layer transparent conductive oxide structures, effectively using a simpler, more cost-effective material solution to achieve the required electrode performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the alignment and support of substrates, preventing light leakage and ensuring high-quality display by maintaining uniformity and stability of the display panel even under external forces.
Implementation Method 1
the low-work-function metal film has a work function of 4.0 eV to 5.0 eV and emits electrons, thereby forming an electron cloud
Data Source
Figure 1~3
AI summary
The application discloses an array substrate, comprising a base, a conductive pattern layer disposed on the base, a transparent electrode layer, and an insulating layer disposed between the conductive pattern layer and the transparent electrode layer, the conductive pattern layer comprises a plurality of first conductive patterns, the transparent electrode layer comprises a plurality of transparent electrodes, each of the transparent electrodes is electrically coupled to a corresponding one of the first conductive patterns through a corresponding via hole in the insulating layer, wherein at a position where at least one via hole is located, a stepped structure is formed between the first conductive pattern corresponding to the via hole and the base and/or the insulating layer such that a groove is formed at an upper surface of the array substrate at a position corresponding to the via hole. The application further discloses a display device. The array substrate provided by the application can prevent sliding and misalignment between the array substrate and an opposite substrate.