Curved Display Spacer Design for Substrate Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Display devices with curved structures face misalignment issues between substrates due to differences in curvature radii, leading to uneven cell gaps and potential deterioration of display quality.
Innovation Solution
Incorporating spacers with a silicon-based polymer compound, such as polydimethylsiloxane (PDMS), that protrude from one substrate and feature pillar portions and contact portions to maintain a consistent cell gap and adhere to the opposing substrate, preventing misalignment during bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional spacers are used in curved display devices, then the substrates can be curved, but misalignment between substrates occurs due to differences in curvature radii
Solution Approach 1:
The spacer structure is divided into different portions with different functions: the spacer body portion maintains the cell gap, while the contact portions with enlarged cross-sectional areas provide precise positioning and adherence to the opposite substrate. This local differentiation of structure and function resolves the alignment issue in curved displays.
Solution Approach 2:
The contact portions are formed with enlarged cross-sectional areas before the substrates are assembled. This preliminary structuring ensures that when the substrates are curved, the contact portions can pre-establish proper alignment and contact points, preventing misalignment during the curving process.
2Manufacturing precision
If the cell gap is maintained uniformly in curved structures, then display quality is improved, but the spacer structure becomes more complex
Solution Approach 1:
The spacer is segmented into a spacer body portion and multiple contact portions. The spacer body portion maintains the overall cell gap, while the distributed contact portions ensure uniform spacing across the curved surface. This segmentation allows uniform cell gap maintenance without requiring a completely complex spacer design.
Solution Approach 2:
The spacer is made from an elastomeric material that can flex and conform to curved substrate surfaces. This flexibility allows the spacer to maintain uniform cell gap in curved structures without requiring complex rigid structures, thus improving display quality while controlling device complexity.
3Reliability
If spacers with enlarged contact portions are used, then substrate adhesion is improved, but fabrication processes become more complex
Solution Approach 1:
The cross-sectional area of the contact portions is changed (enlarged) compared to the spacer body portion. This parameter change in the spacer geometry improves adhesion to the opposite substrate while the elastomeric material allows this structural change to be achieved through standard fabrication processes like molding or deposition, balancing adhesion improvement with manufacturing ease.
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
The spacers effectively maintain a uniform cell gap and prevent misalignment between substrates, enhancing display quality and simplifying the fabrication process while reducing costs.
Implementation Method 1
The spacer may include a material capable of elastic deformation
Data Source
AI summary
A display device includes a first substrate, a second substrate opposite to the first substrate, a liquid crystal layer between the first substrate and the second substrate, and a plurality of spacers maintaining a cell gap between the first substrate and the second substrate. Each of the plurality of spacers includes a spacer body portion protruding from the first substrate, and a spacer pattern portion including a plurality of pillar portions protruding from the spacer body portion and a plurality of contact portions respectively on top ends of the plurality of pillar portions so as to be in contact with a bottom surface of the second substrate.