Display Substrate Column Spacer Height Variation
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Solution Overview
Problem
Current display technologies face challenges in achieving high aperture ratio and transmittance while effectively forming black matrices and column spacers simultaneously, which are crucial for modern electronic display devices requiring low driving voltage and low power consumption.
Innovation Solution
A display substrate design where first and second pixel areas with distinct light-blocking regions include insulating layers, black matrix pattern layers, and column spacers of varying heights, allowing for increased aperture ratio and transmittance, and a method of manufacturing that forms these features simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If black matrices and column spacers are formed simultaneously using conventional methods, then manufacturing process simplicity is maintained, but aperture ratio and transmittance are reduced due to overlapping formation limitations
Solution Approach 1:
The patent segments the formation process into distinct stages: first forming the black matrix pattern layer, then subsequently forming column spacers in separate regions. This segmentation allows independent optimization of each component's formation, enabling precise control over spacer positioning and height without compromising the black matrix quality, thereby increasing aperture ratio while maintaining process manageability
Solution Approach 2:
The patent applies preliminary action by first forming the black matrix pattern layer and establishing it as a foundation before forming the column spacers. The black matrix pattern layer serves as a pre-prepared structure that guides subsequent spacer formation, allowing the spacers to be positioned precisely relative to the black matrix regions, thus achieving high aperture ratio without requiring complex simultaneous formation processes
2Reliability
If column spacers of uniform height are used, then manufacturing simplicity is maintained, but device durability is reduced due to inability to distribute external forces effectively
Solution Approach 1:
The patent applies local quality by varying the height of column spacers according to their specific positional requirements within the display device. Different regions have spacers of different heights, allowing each location to be optimized for its local stress conditions and functional requirements. This localized optimization enhances overall device durability by distributing external forces more effectively across the structure, while the variation is implemented through controlled formation processes that maintain manufacturing feasibility
3Use of energy by moving object
If aperture ratio is increased to reduce power consumption, then transmittance improves, but black matrix and column spacer formation becomes more difficult
Solution Approach 1:
The patent uses preliminary action by first establishing the black matrix pattern layer with optimized dimensions and positioning before forming the column spacers. This pre-established pattern layer serves as a template that guides spacer formation, allowing the spacers to be positioned precisely in the remaining active areas. This sequential approach with preliminary preparation enables increased aperture ratio while maintaining high formation precision, as each component is formed with optimal parameters independent of the other
Solution Approach 2:
The patent segments the formation process to allow independent optimization of black matrix and column spacer dimensions. By forming them in separate stages rather than simultaneously, each component can be precisely controlled according to its specific requirements for maximizing aperture ratio. The segmentation enables precise control over the boundaries and dimensions of both structures, ensuring high formation precision even as the aperture ratio is increased to reduce power consumption
Data Source
AI summary
A display substrate includes a substrate on which a first pixel area including a first light-blocking region, and a second pixel area adjacent to the first pixel area and including a second light-blocking region are defined, an insulating layer in the first and second light-blocking regions, a black matrix pattern layer on the insulating layer, a first column spacer in the first light-blocking region and protruding from the black matrix pattern layer, and a second column spacer in the second light-blocking region and protruding from the black matrix pattern layer. A height of a top surface of the first column spacer is different from a height of a top surface of the second column spacer, where the heights are taken with respect to the substrate.