Display Substrate Insulation Layer Segmentation for Outgassing Control
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Solution Overview
Problem
In liquid crystal display (LCD) manufacturing, the misalignment between the TFTs substrate and the color filter substrate leads to decreased image quality due to outgassing issues, causing non-uniform cell gaps and incomplete filling of liquid crystal molecules, which existing technologies fail to adequately address.
Innovation Solution
A display substrate design featuring a first display substrate with a color filter and backflow-blocking patterns on its peripheral area, covered by an insulation layer with holes, allowing for testing and corrective action before filling liquid crystal molecules, ensuring complete filling and preventing outgassing-related defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an inorganic insulation layer is formed on the COA color filter layer to prevent outgassing, then harmful chemical outgassing is prevented, but the compressibility of the color filter layer decreases leading to non-uniform cell gaps
Solution Approach 1:
The patent divides the insulation layer into two functional regions: a first insulation layer directly covering the color filter layer (providing outgassing prevention), and a second insulation layer covering the first insulation layer and containing through-holes (providing compression capability). This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The first insulation layer acts as an intermediary between the color filter layer and the second insulation layer. It provides outgassing prevention while allowing the second insulation layer to compress it, thus mediating between the conflicting requirements of outgassing prevention and compression capability.
2Object-affected harmful factors
If a hard inorganic insulation layer is formed on the color filter layer, then outgassing is prevented, but liquid crystal molecule filling becomes incomplete
Solution Approach 1:
The insulation structure is segmented into two layers with different properties: the first insulation layer (hard, outgassing prevention) and the second insulation layer (softer, compressible with through-holes). This segmentation resolves the contradiction between outgassing prevention and liquid crystal filling completeness.
Solution Approach 2:
The second insulation layer contains through-holes that serve as channels for liquid crystal molecule infiltration. This porous structure allows liquid crystal molecules to reach areas that would otherwise be inaccessible due to the rigid first insulation layer, ensuring complete filling.
3Object-affected harmful factors
If the color filter layer is made more rigid to prevent outgassing, then chemical contamination is reduced, but the spreadability of liquid crystal molecules decreases
Solution Approach 1:
The patent segments the insulation function between two layers: the first insulation layer provides chemical contamination prevention with its rigid structure, while the second insulation layer provides liquid crystal spreadability with its softer, porous structure containing through-holes.
Solution Approach 2:
Different regions of the insulation structure have different local qualities: the first insulation layer has high rigidity for outgassing prevention, while the second insulation layer has lower rigidity and porous structure for liquid crystal infiltration. This local quality differentiation resolves the contradiction.
Data Source
AI summary
A display substrate includes a first display substrate comprising a display area having an array of switching elements and a peripheral area surrounding the display area, a second display substrate facing the first display substrate, a color filter disposed on the display area of the first display substrate, a first backflow-blocking pattern including a material substantially the same as the color filter and disposed on the peripheral area and an insulation layer covering the color filter and the first backflow-blocking pattern, the insulation layer having a hole exposing, for outgas testing purposes, a corresponding portion of the first backflow-blocking pattern.