Display Spacer Layout Over Dual Flattening Films Near Contact Holes
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Solution Overview
Problem
The stability of spacers in display devices is compromised due to variations in the thickness of flattening films and solidification states, leading to potential irregularities in the distance regulation between array and counter substrates, especially when spacers are adjacent to contact holes.
Innovation Solution
The implementation of a display device design where spacers made of resin are strategically positioned at intersections of signal and scanning lines, with a thicker first flattening film filling contact holes and a thinner second flattening film overlapping scanning lines, ensuring stable spacer thickness and accurate distance regulation between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spacer is adjacent to the contact hole, then the solidification state of the spacer changes in accordance with the thickness of the flattening film, but the shape of the spacer becomes potentially unstable
Solution Approach 1:
The patent divides the flattening film into two distinct layers: a first flattening film that fills the recessed part of the contact hole, and a second flattening film that forms a flat surface. This segmentation allows each layer to serve its specific function independently, preventing the spacer shape from being affected by variations in the first layer's thickness while maintaining manufacturing flexibility.
Solution Approach 2:
The second flattening film acts as an intermediary layer between the first flattening film and the spacer. It provides a stable, flat surface for spacer formation, isolating the spacer from the thickness variations of the first flattening film and ensuring consistent spacer shape regardless of contact hole depth variations.
2Measurement precision
If the spacer is directly formed on the array substrate by resin molding, then the overlapping error with the array substrate is reduced, but the solidification state changes with flattening film thickness causing shape instability
Solution Approach 1:
The flattening film is segmented into two functional layers: the first layer fills the contact hole recess to provide electrical coupling, while the second layer creates a uniform flat surface. This segmentation decouples the alignment function from the filling function, allowing the spacer to be precisely positioned on the flat second layer without being influenced by the variable thickness of the first layer.
Solution Approach 2:
The second flattening film serves as an intermediary substrate for spacer formation. It provides a stable, flat surface that ensures precise spacer positioning and alignment with the array substrate, while isolating the spacer from the thickness variations inherent in the contact hole filling process.
Data Source
AI summary
A display device includes an array substrate, and a counter substrate. The array substrate includes a plurality of signal lines arranged at an interval in a first direction, a plurality of scanning lines arranged at an interval in a second direction, a color filter, a plurality of pixel electrodes disposed for respective pixels, a common electrode superimposed on the plurality of pixel electrodes with an insulating film interposed between the common electrode and the plurality of pixel electrodes, and an insulating film covering the color filters. A contact hole is a recessed part opened through the insulating film and electrically couples the pixel electrode and the semiconductor, and a first flattening film is insulating and fills the recessed part of the contact hole.