Double-Layer Photo Spacer for Liquid Crystal Display Panel
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Solution Overview
Problem
Conventional liquid crystal display panels suffer from pixel light leakage and local uneven dark state displays due to the single-layer organic resin material used for spacers, which affects display quality, and these issues cannot be adequately addressed by adjusting the photo spacer critical dimension and height.
Innovation Solution
A liquid crystal display panel with a double-layer photo spacer structure, where the support spacer is made of a tough organic resin material and the buffer spacer is made of a highly elastoplastic and frictional organic resin material, both formed through a same photomask process, with the buffer spacer contacting the array substrate to prevent shifting and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer organic resin material is used for the photo spacer, then the manufacturing process is simple, but pixel light leakage and local uneven dark state displays occur affecting display quality
Solution Approach 1:
The photo spacer is divided into two distinct layers: a support spacer layer (first organic resin material) and a buffer spacer layer (second organic resin material). Each layer serves a specific function - the support layer provides structural integrity while the buffer layer prevents breakthrough, thereby eliminating display quality issues without significantly complicating the manufacturing process.
Solution Approach 2:
The photo spacer uses a composite structure combining two different organic resin materials with complementary properties. The first material provides toughness and support strength, while the second material provides elastoplasticity and breakthrough prevention, creating a composite spacer that solves both structural support and display quality requirements.
2Strength
If the photo spacer is made with high toughness material to provide sufficient support force, then the support strength is improved, but the material may break through the polyimide film under vibration causing light leakage
Solution Approach 1:
The spacer function is segmented into two layers: the support spacer layer provides the necessary support strength to maintain cell gap, while the buffer spacer layer specifically addresses vibration resistance by preventing polyimide film breakthrough through its elastoplastic properties.
Solution Approach 2:
Different regions of the photo spacer have different material properties optimized for their specific functions. The support spacer region uses high-toughness material for structural support, while the buffer spacer region uses high-elastoplasticity material for vibration absorption and breakthrough prevention, creating local quality differentiation that solves both contradictions.
3Manufacturing precision
If the photo spacer critical dimension and height are adjusted to ensure sufficient LC margin, then the liquid crystal filling is improved, but moving Mura effects and panel shifting still occur
Solution Approach 1:
The dual-layer spacer structure provides differentiated functionality where the buffer spacer layer specifically addresses panel stability by preventing breakthrough and reducing shifting, while the support spacer layer maintains the cell gap for proper liquid crystal margins, thus solving both manufacturing precision and alignment stability issues.
Solution Approach 2:
The composite spacer structure combines materials with different mechanical properties to simultaneously achieve proper cell gap maintenance (for LC margin) and enhanced stability (to prevent shifting and Mura effects). The combination of toughness and elastoplasticity in different layers addresses both requirements.
Data Source
AI summary
A liquid crystal display panel includes an array substrate and a color filter substrate which are arranged opposite to each other, and a liquid crystal layer. The color filter substrate includes a second substrate, a black matrix, a color resist layer, and photo spacers arranged on a common electrode. The photo spacers are arranged directly under the black matrix. The photo spacer includes a support spacer arranged on the common electrode and a buffer spacer arranged on the support spacer.