LCD Column Spacer Adhesive Bonding for Gap Control
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Solution Overview
Problem
In large-sized LCD devices, external pressure causes the gap between substrates to change, leading to defects on the display screen, and existing solutions like pressure and heat treatments deform column spacers, while adhesive layers increase manufacturing costs and yield issues.
Innovation Solution
A method involving forming column spacers and a sidewall on one substrate, applying an adhesive solution with an organic solvent, and bonding them to the opposing substrate by drying the solvent, ensuring precise gap control and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure and heat treatments are applied to bond the column spacer to the substrate, then the column spacer is bonded to the substrate, but the column spacer is deformed due to pressure
Solution Approach 1:
The patent changes the bonding method from pressure and heat treatment to adhesive bonding. The adhesive layer is formed on the column spacer surface, and the spacer is bonded to the substrate by the adhesive properties of the layer, eliminating the need for pressure and heat that cause deformation.
Solution Approach 2:
The adhesive layer acts as an intermediary between the column spacer and the substrate. This intermediate layer provides bonding without requiring direct pressure contact, thus preventing spacer deformation while achieving strong adhesion.
2Strength
If an adhesive layer is formed by printing on the column spacer, then the column spacer is bonded to the substrate, but additional manufacturing steps are necessary, increasing cost and decreasing yield
Solution Approach 1:
The patent merges the adhesive layer formation with the existing column spacer manufacturing process. The adhesive layer is formed as part of the spacer structure, eliminating the need for separate printing steps and reducing manufacturing complexity.
Solution Approach 2:
The adhesive layer serves multiple functions: it provides bonding between the spacer and substrate, and it is integrated into the spacer manufacturing process itself. This multi-functionality reduces the need for additional separate processes.
3Ease of manufacture
If the column spacer is not bonded to the substrate, then the manufacturing process is simple, but the gap between substrates changes due to external pressure
Solution Approach 1:
The patent changes the bonding mechanism from mechanical bonding (adhesive printing) to chemical bonding (adhesive layer). This provides more reliable and uniform bonding that maintains gap stability under external pressure while keeping the manufacturing process simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, achieves uniform cell gaps, and reduces the substrate interval, improving display quality and reducing manufacturing costs by ensuring strong and uniform adherence of spacers without deforming them.
Implementation Method 1
adhering the column spacers to the second substrate by drying the organic solvent from the adhesive solution
Data Source
AI summary
A method for manufacturing a liquid crystal display (LCD) device includes preparing first and second substrates, at least one of the first and second substrates being a transparent substrate; forming a plurality of the column spacers on the first substrate for maintaining a cell gap between the first and second substrates and a sidewall on the first substrate for sealing the periphery of the substrates; applying an adhesive solution including an adhesive diluted with an organic solvent onto the first substrate having the column spacers and the sidewall thereon; positioning the second substrate on the first substrate so that the first and second substrates face each other; adhering the column spacers to the second substrate by drying the organic solvent from the adhesive solution; and providing a liquid crystal material between the first and second substrates.