Color Filter Substrate Spacer Compression via Pillow Layer
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Solution Overview
Problem
In large-sized liquid crystal display panels, the compression amount of spacers is limited, leading to a risk of gravity Mura and increased material costs, as the thickness of the auxiliary pillow layer is fixed and the height of the spacer is constrained, making it difficult to achieve continuous change in compression amounts.
Innovation Solution
A color filter substrate with a pillow layer between the spacers and the black matrix, allowing for flexible control of the compression amount by varying the thickness of the pillow layer, which can be formed using photosensitive or non-photosensitive black resin, enabling continuous adjustment of the spacer's compression force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the auxiliary pillow layer is increased to increase the compression amount of the main spacer, then the ability to prevent gravity Mura is improved, but the thickness is fixed by the functional film layers and cannot be changed continuously
Solution Approach 1:
The invention divides the pillow layer into two separate components: a first pillow layer formed together with the black matrix, and a second pillow layer formed separately on the first pillow layer. This segmentation allows independent control of each layer's thickness, enabling continuous adjustment of the total compression amount without being constrained by fixed functional film layer thicknesses.
Solution Approach 2:
The invention introduces a dynamic adjustment mechanism by forming the second pillow layer with a thickness that can be continuously varied. This allows the compression amount of the main spacer to be dynamically adjusted according to different requirements, transforming a static system into a flexible one that can adapt to various compression needs.
2Force
If the height of the spacer is increased to achieve larger compression amount, then the compression force is improved, but the diameter is constrained by space on the array substrate and black matrix size
Solution Approach 1:
Instead of increasing the spacer height (vertical dimension) which is constrained by available space, the invention increases the pillow layer thickness (horizontal dimension before compression). This dimensional shift allows achieving the same compression effect without increasing spacer height, thereby avoiding the constraints on spacer diameter caused by limited space on the array substrate.
3Reliability
If multiple different types of spacers are used to prevent mura in large-sized panels, then the display quality is improved, but the device complexity and material costs increase
Solution Approach 1:
The invention forms the first pillow layer together with the black matrix in advance, creating a stable base structure. Then the second pillow layer is formed on top to provide additional compression. This preliminary action of creating the first pillow layer simplifies the overall structure by pre-establishing part of the compression mechanism, reducing the need for multiple complex spacer types.
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 reduces the risk of gravity Mura, enhances picture display quality, and allows for flexible design and manufacturing of spacers, improving the reliability and efficiency of the display device while reducing material costs.
Implementation Method 1
coating a photosensitive black resin layer; exposing the photosensitive black resin layer by a dual-tone mask
Data Source
AI summary
A display panel includes: a color filter substrate including a first base substrate, a black matrix disposed on the first base substrate, and a plurality of spacers disposed on the black matrix a pillow layer provided at least part of the spacers and the black matrix; an array substrate cell-assembled with the color filter substrate, wherein at least part of spacers disposed on the pillow layer is in contact with the array substrate by pressing.