Flexible Display Panel Substrate Alignment via Light Shielding Film
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Solution Overview
Problem
In liquid crystal display panels using a flexible resin base, substrates tend to shift in position during manufacturing processes, leading to misalignment of pixel electrodes and color filters, which results in inadequate light transmission to the color filter and compromised image display, especially when the display panel is curved or bent.
Innovation Solution
The solution involves forming a color filter on a separate rigid substrate and bonding it to a first substrate with an adhesive layer, ensuring high-strength bonding and preventing shifts, while the pixel electrode is formed on a first resin base, and the color filter is positioned closer to the viewer than the liquid crystal layer, with a phase difference compensation system to maintain image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible resin base is used to enable thinning and curving of the display panel, then the display panel can be thinned and curved at its end portion, but substrates shift in position during manufacturing processes and when curved, leading to misalignment of pixel electrodes and color filters
Solution Approach 1:
The invention divides the substrate structure into multiple layers: a flexible resin base, a first substrate with pixel electrode, a second substrate with color filter, and a light shielding film. This segmentation allows each layer to perform its specific function while maintaining overall alignment. The light shielding film is segmented to extend from the first substrate to the second substrate, creating a structural reference that prevents relative shifting between substrates during manufacturing and when curved.
Solution Approach 2:
The light shielding film acts as an intermediary element between the first substrate and the second substrate. It provides a structural connection and alignment reference that prevents the substrates from shifting relative to each other. The light shielding film mediates the relationship between the flexible resin base (which causes shifting) and the substrate alignment (which requires precision), allowing both flexibility and precision to coexist.
2Ease of manufacture
If substrates are bonded with only a sealant having small width at their periphery region, then the liquid crystal layer can be properly contained, but the substrates may shift in position during manufacturing processes and when curved
Solution Approach 1:
The invention extends the light shielding film from the first substrate into the liquid crystal layer region and onto the second substrate, creating a three-dimensional structural reference. This dimensional extension provides a stability mechanism that operates independently from the peripheral sealant bonding, preventing substrate shifting during manufacturing and when the display panel is curved while maintaining the simple sealant-based bonding structure.
3Illumination intensity
If the color filter is positioned closer to the viewer than the liquid crystal layer, then light transmission to the color filter is improved, but substrate shifts cause light to not be properly irradiated to the color filter
Solution Approach 1:
The light shielding film is formed in advance to create a structural framework that defines the relative positions of the first substrate and second substrate. This preliminary structural establishment ensures that when the pixel electrode and color filter are formed on their respective substrates, they will be properly aligned. The light shielding film's extension into the liquid crystal layer region pre-establishes the correct spatial relationship, ensuring light properly reaches the color filter even when positioned closer to the viewer.
Data Source
AI summary
A display panel including a first substrate including a pixel electrode, a second substrate, a third substrate, a liquid crystal layer between the first substrate and the second substrate, and a color filter. The first substrate is located between the liquid crystal layer and the color filter. The first substrate includes a first resin base, or the second substrate includes a second resin base. A display panel may include a first polarizer plate. The third substrate may be located between the first substrate and the first polarizer plate.