Display Sealant Layer Capillary Drain Cavity Stain Prevention
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Solution Overview
Problem
The manufacturing process of flat panel display apparatuses, such as liquid crystal displays, is complex and costly due to the need for spacers to maintain substrate distance and ensure liquid crystal-carrying capacity, which can lead to liquid crystal being perceived as stains.
Innovation Solution
A display apparatus and method that includes a base substrate with pixel rows, active cavities, and drain cavities, utilizing capillary forces to fill and seal liquid crystal, with a sealant layer to absorb remaining liquid crystal and prevent staining, thereby securing a margin in liquid crystal-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spacer is formed on one of the two substrates to maintain the distance between the two substrates, then the distance between substrates is maintained and liquid crystal-carrying capacity is ensured, but the manufacturing process becomes complicated and manufacturing cost is increased
Solution Approach 1:
The patent removes the spacer component entirely from the display structure. Instead of adding a spacer to maintain substrate distance, the invention uses the sealant layer itself to perform both sealing and spacing functions, thereby eliminating the need for separate spacers and simplifying the manufacturing process while maintaining liquid crystal-carrying capacity
Solution Approach 2:
The sealant layer is designed to perform multiple functions simultaneously: it seals the edge of the liquid crystal layer, maintains the distance between substrates, and provides liquid crystal-carrying capacity. This multi-functional design eliminates the need for separate spacer components and reduces manufacturing complexity
2Reliability
If a spacer is formed on one of the two substrates to maintain the distance between the two substrates, then the distance between substrates is maintained, but manufacturing cost is increased
Solution Approach 1:
The patent eliminates the spacer component and its associated manufacturing costs. The sealant layer alone performs the substrate distance maintenance function, removing the need for separate spacer materials and assembly steps, thereby reducing manufacturing cost
Solution Approach 2:
The sealing function and spacing function are merged into a single component - the sealant layer. This consolidation eliminates the need for separate spacer components and reduces the number of manufacturing steps and materials required, thereby reducing manufacturing cost
3Quantity of substance
If liquid crystal is provided in sufficient quantity to ensure carrying capacity, then liquid crystal-carrying capacity is secured, but liquid crystal may be perceived as stains
Solution Approach 1:
The patent creates different capillary force characteristics in different regions: the trench has high capillary force to draw liquid crystal, while the drain cavity has low capillary force to contain excess liquid crystal. This localized quality differentiation allows sufficient liquid crystal to be provided without causing staining, as the excess is contained in the drain cavity rather than spreading across the display area
Solution Approach 2:
The drain cavity acts as an intermediary structure that receives and contains excess liquid crystal. By providing this intermediate containment zone, the system can hold sufficient liquid crystal for carrying capacity while preventing it from spreading to areas where it would be perceived as stains
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
Simplifies the manufacturing process, reduces costs, and ensures effective liquid crystal distribution and sealing, preventing liquid crystal from being perceived as stains within the display apparatus.
Implementation Method 1
moving the liquid crystal into the active cavity and the drain cavity using a capillary force to form a liquid crystal layer in the active cavity and the drain cavity
Implementation Method 2
the capillary force decreases from the active cavity, the drain cavity, and the trench, and the liquid crystal in the trench moves to the drain cavity after being filled in the active cavity by a capillary force difference
Data Source
AI summary
A display apparatus and a method of manufacturing a display apparatus are disclosed. A display may include a base substrate, a plurality of pixel rows each of which includes a plurality of pixels arranged both in a first direction and in a second direction, a sealant layer covering the pixel rows, and a trench disposed between the pixel rows. Each pixel row may include a plurality of active cavities arranged along the trench and a drain cavity disposed on at least one end of the trench. A capillary force decreases along the active cavities, the drain cavity, and the trench.