Display Device Spacer Configuration for Cell Gap Stability
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Solution Overview
Problem
Liquid crystal display devices face alignment defects and light leakage due to displacement of spacers under external pressure, which can damage the alignment film and affect display quality.
Innovation Solution
The use of a main spacer and sub-spacer configuration, where the main spacer is located in a concavity between the substrates and maintains the cell gap, while the sub-spacer is separated and positioned to overlap with the light-shielding layer, preventing damage to the alignment film and reducing light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single spacer is used to maintain cell gap, then the device structure is simple, but the spacer may displace under external pressure causing alignment film damage and light leakage
Solution Approach 1:
The spacer structure is divided into a first spacer and a second spacer positioned at different locations between the substrates. The first spacer maintains the cell gap in the display area, while the second spacer is positioned in the non-display area to prevent edge leakage. This segmentation allows each spacer to perform its specific function independently, preventing displacement-related damage to the alignment film while maintaining overall structural reliability.
2Area of stationary object
If the light-shielding layer is made small to improve display area, then the display area increases, but light leakage occurs around the spacers
Solution Approach 1:
The second spacer acts as an intermediary element positioned in the non-display area between the substrates. It physically blocks the liquid crystal molecules from leaking at the edges without requiring the light-shielding layer to extend into the display area. This intermediary spacer effectively prevents light leakage while preserving the maximum display area.
3Object-generated harmful factors
If the light-shielding layer is enlarged to cover spacers, then light leakage is prevented, but the display area is reduced
Solution Approach 1:
The light-shielding function is segmented between two components: the light-shielding layer in the display area and the second spacer in the non-display area. The light-shielding layer only needs to cover the first spacer in the display area, while the second spacer handles the edge leakage prevention. This segmentation allows the light-shielding layer to remain compact, maximizing display area while still preventing light leakage.
4Strength
If external pressure is applied to the substrate, then the cell may be sealed tightly, but the spacer displaces causing alignment defect
Solution Approach 1:
Different spacers are positioned at different locations with different functional requirements. The first spacer in the display area is optimized for maintaining cell gap stability, while the second spacer in the non-display area is optimized for preventing edge leakage under pressure. This local quality differentiation ensures that each spacer maintains its position stability under external pressure while performing its specific function.
Data Source
AI summary
According to one embodiment, a display device includes a first substrate including a first relay electrode, a second relay electrode, and a first insulating layer including a first contact hole penetrated to the first relay electrode and a second contact hole penetrated to the second relay electrode, a second substrate opposed to the first substrate, and a main spacer located between the first substrate and the second substrate, the first insulating layer further including a first concavity located between the first contact hole and the second contact hole, the main spacer being located in the first concavity, and maintaining a cell gap between the first substrate and the second substrate.