Display Substrate Groove Layout for Alignment Layer Overflow Control
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Solution Overview
Problem
Existing display panel manufacturing processes face challenges in controlling the placement of the alignment layer end portion in the non-display area, leading to increased bezel size and complexity, which affects the coupling strength between the sealant and the display substrate.
Innovation Solution
A display substrate design that incorporates a groove formed during the patterning process of the organic and inorganic layers, allowing the alignment layer end portion to be positioned within the groove, reducing the overlapping area with the sealant and enhancing coupling strength without requiring additional masks, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the alignment layer is allowed to spread freely in the non-display area, then the alignment layer can be easily applied, but the overlapping area with sealant increases and coupling strength decreases
Solution Approach 1:
The non-display area is segmented into a groove region and a sealant application region. The groove physically divides the space, preventing the alignment layer from spreading into the sealant area while maintaining easy alignment layer application in the designated region.
Solution Approach 2:
The groove extracts or removes the problematic overlapping area by creating a physical barrier. The alignment layer is confined to the display area and cannot encroach into the sealant region, eliminating the source of weak coupling.
2Strength
If a groove structure is added to control alignment layer placement, then coupling strength increases, but manufacturing complexity increases due to additional masks
Solution Approach 1:
The groove formation process is merged with the existing organic layer patterning process. The same photomask and etching steps used to define the organic layer patterns are also used to define the groove, eliminating the need for separate masks and processes.
Solution Approach 2:
The photomask serves multiple functions: it defines both the organic layer patterns and the groove structure. This multi-functionality reduces the total number of masks required and simplifies the manufacturing process.
3Area of stationary object
If the non-display area is reduced to provide a slim bezel, then the display appearance is improved, but controlling alignment layer placement becomes more difficult
Solution Approach 1:
The solution moves from two-dimensional planar control to three-dimensional control by introducing a groove with depth. This vertical dimension provides an additional degree of freedom for confining the alignment layer without increasing the horizontal footprint.
Solution Approach 2:
The groove introduces local structural variation in the non-display area, creating a specific region with different physical properties (confined space) that controls alignment layer placement locally without affecting the overall small non-display area.
Data Source
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AI summary
A display substrate includes a base substrate and a plurality of insulating layers disposed on a surface of the base substrate. A groove is defined in the insulating layers in a non-display area of the display substrate. An end portion of an alignment layer is disposed in the groove. The groove is capable of controlling a flow of a liquid alignment material to prevent the liquid alignment material from overflowing to an edge of the base substrate. The groove is formed simultaneously in a process of forming contact holes in a display area of the display substrate. Accordingly, a structure corresponding to the end portion of the alignment layer to control the flow of the liquid alignment material is formed without increasing the number of masks.