Color Filter Post Projections for LCD Spacer Bonding
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Solution Overview
Problem
The conventional method of using post spacers in liquid crystal displays (LCDs) faces issues with weak bonding between the post spacers and the underlying common electrode layer, leading to display nonuniformity, light leakage, and touch mura due to parallel offset under external pressure, which affects display performance and compression resistance.
Innovation Solution
The use of post projections formed in the color filter layer as spacers, which provide stronger non-metal to non-metal material bonding, enhancing the bonding force and eliminating the need for a separate photolithography process for post spacer formation, thereby improving display performance and compression resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post spacers are formed with photoresist on the common electrode layer, then the cell gap can be maintained, but the bonding force between post spacers and the underlying layer is weak, causing parallel offset under external pressure
Solution Approach 1:
The invention segments the post spacer formation process by creating post projections directly within the color filter layer material itself, rather than forming separate post spacers on top of the common electrode layer. This integration ensures that the post projections become an inherent part of the color filter layer structure, providing strong mechanical bonding and preventing parallel offset under external pressure.
Solution Approach 2:
The invention merges the functions of the color filter layer and the post spacer structure by forming post projections directly within the color filter layer material. This combination eliminates the need for separate post spacer layers and their associated photolithography processes, while ensuring strong bonding between the post projections and the underlying common electrode layer through the integrated structure.
2Manufacturing precision
If a separate photolithography process is used to form post spacers, then the position and height can be precisely controlled, but the production process complexity increases
Solution Approach 1:
The invention merges the color filter layer formation process with the post spacer formation process by creating post projections directly within the color filter layer material during the same manufacturing steps. This integration eliminates the need for separate photolithography processes that would be required to form distinct post spacer structures, thereby reducing production process complexity while maintaining precise control over post projection position and height through the color filter layer patterning process.
Solution Approach 2:
The color filter layer material serves multiple functions: it provides the color filtering function and simultaneously forms the post projections that serve as spacers. This multi-functionality eliminates the need for separate dedicated spacer materials and processes, simplifying the overall manufacturing process while maintaining the necessary precision for cell gap control.
3Ease of manufacture
If ball spacers are sprayed during assembly, then the process is simple and cost-effective, but the number and positions are difficult to control and they aggregate easily
Solution Approach 1:
The invention segments the spacer function into localized post projections that are inherently formed as part of the color filter layer structure at specific pixel locations. This eliminates the need for spraying ball spacers during assembly, providing both the simplicity of an integrated process and the precision of predetermined spacer positions and quantities defined by the color filter layer design.
Data Source
AI summary
The disclosed technology discloses a color filter substrate comprising a base substrate, a black matrix, a color filter layer and a common electrode layer; wherein the color filter layer has post projection(s) formed therewith. The post projections function as post spacers to support and maintain the cell gap of a liquid crystal cell between the array substrate and color filter substrate.