Flat Panel Display Bonding Structure with Separation Walls
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Solution Overview
Problem
In liquid crystal on silicon (LCOS) flat panel displays, maintaining a constant cell gap is challenging due to different thermal properties of substrates, leading to image quality issues and non-uniformity, especially with conventional spacers causing liquid crystal orientation defects and increased panel size.
Innovation Solution
A bonding structure with outer and inner separation walls of equal heights, formed from silicon oxide, is arranged along the edges of substrates with a predetermined interval, and a sealant is applied between these walls to maintain a constant cell gap, preventing sealant infiltration and thermal expansion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spacer is applied in the active area to maintain cell gap, then the cell gap uniformity is improved, but the liquid crystal arrangement is disturbed causing image damage
Solution Approach 1:
The invention extracts the spacer from the active area and relocates it to the inter-pixel area. The separation wall structure is formed only in the inter-pixel region, eliminating the harmful effect on liquid crystal arrangement while maintaining cell gap uniformity through the separation wall's physical barrier function.
Solution Approach 2:
The separation wall acts as an intermediary structure between the upper and lower substrates in the inter-pixel area. It provides the necessary cell gap maintenance function without directly contacting or disturbing the liquid crystal in the active area, thus mediating between the need for uniform cell gap and the requirement for undisturbed liquid crystal arrangement.
2Manufacturing precision
If a post is disposed on the inter-pixel area to maintain cell gap, then the cell gap is maintained, but the inter-pixel size increases and panel size becomes larger
Solution Approach 1:
The separation wall is designed with localized functionality - it is formed only in the inter-pixel area where cell gap maintenance is needed, with a width of 1-10 μm. This localized approach maintains cell gap precision without expanding the overall panel area, as the separation wall occupies minimal space compared to conventional posts.
3Manufacturing precision
If the cell gap is maintained by mixing spacer in sealant, then the cell gap is maintained, but the panel deformation cannot be compensated due to different thermal properties of substrates
Solution Approach 1:
The invention extracts the cell gap maintenance function from the sealant mixture and assigns it to a dedicated separation wall structure. The separation wall is formed as a distinct feature in the inter-pixel area, providing stable mechanical support for cell gap maintenance independent of the sealant's thermal properties, thus compensating for substrate thermal expansion differences.
4Speed
If the cell gap is reduced to minimize liquid crystal response time, then the response time is reduced, but optical interference occurs due to different cell gap sizes
Solution Approach 1:
The separation wall structure provides precise mechanical control of the cell gap dimension, ensuring uniform spacing between substrates. This mechanical precision prevents variations in cell gap that would cause optical interference, while maintaining the reduced cell gap dimension necessary for fast liquid crystal response time.
Data Source
AI summary
Provided are a bonding structure for a flat panel display and a method of forming the same, and a flat panel display, including the bonding structure. The bonding structure of a flat panel display device, which is formed between an upper substrate and a lower substrate to seal and bond the two substrates of the flat panel display device, and the bonding structure includes an outer separation wall and an inner separation wall of same heights being arranged along edges of the upper substrate and the lower substrate with a predetermined interval, and a sealant being applied between the outer separation wall and the inner separation wall.