LCD Panel Alignment Protrusions for Cell Gap Maintenance

Solution Overview

Problem

The fabrication of large-size LCD panels is hindered by the need for additional spacers to maintain cell gaps, increasing complexity and cost due to the requirement of separate steps for alignment protrusions and spacers.

Innovation Solution

The integration of alignment protrusions on the second substrate, with some protrusions contacting the first substrate directly and others located in concaves to maintain cell gaps, eliminates the need for additional spacers and simplifies the fabrication process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If alignment protrusions and spacers are fabricated by different fabrication steps, then proper cell gaps are maintained and wide-viewing angle is achieved, but fabrication steps and cost increase

Engineering Contradiction:

Improvecell gap maintenanceVSAvoidfabrication steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the functions of alignment protrusions and spacers into a single integrated structure. The alignment protrusions are designed to serve dual purposes: providing alignment guidance for liquid crystal molecules and maintaining cell gaps between substrates. This merging eliminates the need for separate spacer fabrication steps while achieving both alignment and gap maintenance functions simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alignment protrusions are designed as multi-functional elements that perform multiple roles: (1) aligning liquid crystal molecules in multi-domain configurations for wide-viewing angle, (2) maintaining proper cell gaps between the first and second substrates, and (3) serving as structural reference points during fabrication. This universal design eliminates the need for dedicated spacers and reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If alignment protrusions and spacers are fabricated by different fabrication steps, then proper cell gaps are maintained and wide-viewing angle is achieved, but fabrication cost increases

Engineering Contradiction:

Improvecell gap maintenanceVSAvoidfabrication cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the functions of alignment protrusions and spacers into a single integrated structure. The alignment protrusions are designed to serve dual purposes: providing alignment guidance for liquid crystal molecules and maintaining cell gaps between substrates. This merging eliminates the need for separate spacer fabrication steps while achieving both alignment and gap maintenance functions simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alignment protrusions are designed as multi-functional elements that perform multiple roles: (1) aligning liquid crystal molecules in multi-domain configurations for wide-viewing angle, (2) maintaining proper cell gaps between the first and second substrates, and (3) serving as structural reference points during fabrication. This universal design eliminates the need for dedicated spacers and reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If spacers are added to maintain cell gaps in large-size LCD panels, then cell gap stability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecell gap stabilityVSAvoidstructure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The alignment protrusions are designed as multi-functional elements that perform multiple roles: (1) aligning liquid crystal molecules in multi-domain configurations for wide-viewing angle, (2) maintaining proper cell gaps between the first and second substrates, and (3) serving as structural reference points during fabrication. This universal design eliminates the need for dedicated spacers and reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The alignment protrusions are designed to self-maintain cell gaps through their inherent structural configuration. By positioning the protrusions to contact or approach the opposing substrate, they automatically maintain the designed cell gap distance without requiring additional spacer components or complex assembly procedures.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS8004639B2Liquid crystal display panel

Publication Date: 2011.08.23 AU OPTRONICS CORP

AI summary

An LCD panel includes a first substrate, a second substrate, alignment protrusions and a liquid crystal layer between the first substrate and the second substrate. The first substrate includes pixel units arranged in an array. Each of the pixel units has at least one reflection area and one transmittance area. The first substrate has concaves in the reflection areas. The second substrate is above the first substrate. The first substrate or the second substrate has at least one padding layer in the reflection area. The alignment protrusions having approximately the same height are disposed on the second substrate and located in centers of each of the reflections and the transmittance areas. In the reflection area, a group of the alignment protrusions are in the concaves to keep a gap from the first substrate. The other group of the alignment protrusions outside of the concaves contact with the first substrate directly.