Dual-Shading Layer Display Panel Misalignment
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Solution Overview
Problem
In the manufacturing of display panels, cell-assembly errors between the array substrate and the color filter substrate often lead to light leakage, affecting display quality and reducing yield, as existing shading layers either fail to block data and scanning lines effectively or increase the panel's thickness to compensate, which reduces transmittance.
Innovation Solution
A dual-shading layer approach where a first shading layer is arranged on the array substrate to block data and scanning lines, and a second shading layer is arranged on the color filter substrate to correspondingly block these lines, ensuring effective shading regardless of misalignment during cell-assembly, thereby preventing light leakage and improving yield without compromising transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single shading layer is used on one substrate, then the manufacturing process is simpler, but light leakage occurs due to cell-assembly misalignment
Solution Approach 1:
The single shading layer is divided into two separate shading layers: a first shading layer on the array substrate and a second shading layer on the color filter substrate. This segmentation ensures that even if misalignment occurs during cell assembly, both substrates contribute to blocking light from data and scanning lines, preventing light leakage while maintaining manufacturing feasibility
Solution Approach 2:
The patent applies prior cushioning by pre-compensating for potential misalignment errors. Both the first and second substrates are equipped with shading layers before assembly, creating a redundant shielding system that cushions against the harmful effect of light leakage that would occur if only one substrate had a shading layer
2Reliability
If the shading layer is widened to ensure complete blocking, then light leakage is prevented, but the panel thickness increases and transmittance decreases
Solution Approach 1:
The shading function is segmented between two substrates, allowing each shading layer to be narrower than a single comprehensive shading layer would need to be. The combined effect of both shading layers provides complete blocking without requiring either layer to extend excessively, thus maintaining panel transmittance
Solution Approach 2:
The solution moves from a single-dimension approach (one wide shading layer on one substrate) to a two-dimension approach (two narrower shading layers on different substrates). This dimensional change allows the shading function to be distributed, preventing light leakage without increasing the width or thickness that would reduce transmittance
3Reliability
If misalignment compensation is added to the shading design, then light leakage is prevented, but the device complexity increases
Solution Approach 1:
The shading system is segmented into two independent but coordinated shading layers, each on a different substrate. This segmentation provides inherent misalignment compensation without requiring complex adjustment mechanisms, as each substrate's shading layer independently contributes to the overall blocking function
Solution Approach 2:
Both substrates serve dual functions: they each carry their functional elements (pixel electrodes on array substrate, color filters on color filter substrate) and simultaneously serve as mounting platforms for shading layers. This multi-functionality reduces overall device complexity by integrating shading into existing substrate structures rather than adding separate complex shading mechanisms
Data Source
AI summary
This application discloses a method for manufacturing a display panel, a display panel, and a display device. The display panel includes a first substrate; a second substrate, cell-assembled to the first substrate; and a plurality of data lines and scanning lines, arranged on the first substrate. The first substrate includes a first shading layer blocking the data lines or the scanning lines; the second substrate includes a second shading layer blocking the data lines or the scanning lines; and each of the data lines and the scanning lines is blocked by at least one of the first shading layer and the second shading layer.