Display Panel Spacer Height Gap Mura Prevention
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Solution Overview
Problem
Current liquid crystal display apparatuses, such as TFT-LCDs, face issues with Mura formation due to non-uniform spacer heights, leading to brightness inconsistencies and compromised display quality.
Innovation Solution
The implementation of a display panel with strategically placed spacers and a black matrix that create height gaps between adjacent spacers, utilizing protrusions and photoresist layers to form uniform height differences, and employing a half-tone mask to combine exposure processes, thereby avoiding Mura and enhancing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spacers are manufactured on one side of the array substrate without height gaps, then the manufacturing process is simple, but Mura formation occurs during pressing leading to non-uniform brightness
Solution Approach 1:
The patent applies local quality by creating height gaps only at specific locations between adjacent spacers rather than making all spacers uniform. The black matrix is used to form protrusions at specific positions, creating localized height differences that prevent Mura formation during pressing while maintaining simple overall manufacturing processes.
Solution Approach 2:
The patent implements preliminary action by pre-forming protrusions on the black matrix before spacer placement. These protrusions create the necessary height gaps in advance, ensuring that when spacers are pressed during cell formation, the height differences are already present to prevent Mura formation, thus solving the problem before it occurs.
2Ease of manufacture
If uniform spacer heights are used, then the manufacturing process is straightforward, but brightness uniformity deteriorates due to Mura formation
Solution Approach 1:
The patent introduces local variation in spacer heights by using the black matrix to create protrusions at specific locations. This results in some spacers having height gaps while others maintain uniform heights, creating local quality differences that prevent Mura formation and improve brightness uniformity without complicating the overall manufacturing process.
3Illumination intensity
If multiple exposure processes are used to create height gaps, then brightness uniformity improves, but production efficiency decreases
Solution Approach 1:
The patent merges the black matrix formation and spacer support functions into a single integrated structure. The black matrix serves dual purposes: as a light-blocking element and as a template for creating height gaps through protrusions. This consolidation eliminates the need for separate exposure processes, maintaining brightness uniformity while improving production efficiency.
Solution Approach 2:
The black matrix is designed to perform multiple functions: it blocks light, provides structural support, and creates the height gap pattern through its protrusions. This multi-functionality eliminates the need for additional dedicated structures or processes, thereby maintaining productivity while achieving the brightness uniformity required to prevent Mura formation.
Data Source
AI summary
The present application discloses a display panel and a display apparatus. The display panel includes: a first substrate; a second substrate; and a plurality of spacers, supporting the first substrate and the second substrate, and disposed between the first substrate and the second substrate, where the spacers are disposed at an interval, and the spacers includes a first spacer and a second spacer, a height gap is formed between the first spacer and the second spacer.