LCD Spacer-Through-Hole Structure for Uniform Cell Gaps
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Solution Overview
Problem
In liquid crystal display devices, the increasing demand for finer details in virtual and augmented reality applications leads to spacer sizes becoming negligible compared to pixels, degrading display quality due to the size and arrangement of spacers in relation to cell gaps.
Innovation Solution
The use of organic insulating films with strategically placed through-holes and spacers on both substrates, where the spacers overlap and fill these holes to maintain cell gaps and improve mechanical strength, while reducing spacer size and enhancing display quality by minimizing unevenness around pixel electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are provided on both substrates to maintain cell gaps, then cell gap uniformity is improved, but display quality deteriorates due to spacer size becoming negligible compared to pixel size
Solution Approach 1:
The spacer structure is divided into multiple parts: a first spacer on the first substrate, a second spacer on the second substrate, and a third spacer connecting them. This segmentation allows each spacer component to be optimized independently - the first and second spacers can be made extremely small to match pixel dimensions while the third spacer provides the necessary structural support and cell gap maintenance, resolving the contradiction between small spacer size and sufficient mechanical function.
Solution Approach 2:
The invention transitions from a traditional two-substrate spacer system to a three-dimensional spacer configuration where the third spacer extends vertically to connect the first and second spacers. This dimensional addition allows the horizontal spacers (first and second) to be minimized in size for high-definition display, while the vertical third spacer compensates by providing the necessary structural support and cell gap control.
2Extent of automation
If spacer size is reduced to match high-definition pixel dimensions, then display quality is improved, but mechanical strength deteriorates
Solution Approach 1:
The mechanical support function is segmented from the cell gap definition function. The first and second spacers (on substrates) primarily define cell gaps with minimal size for HD display, while the third spacer (connecting both substrates) carries the mechanical load and provides structural strength. This functional segmentation allows size reduction of display-critical spacers without compromising overall mechanical integrity.
Solution Approach 2:
The spacer system functions as a composite structure where multiple spacer components (first, second, and third spacers) work together to provide both dimensional control and mechanical strength. The combination of these spacer elements creates a composite support system that achieves the necessary mechanical properties while allowing individual spacers to be minimized for high-definition display requirements.
3Extent of automation
If spacers are made negligible in size relative to pixels, then pixel density is improved, but cell gap control deteriorates
Solution Approach 1:
The cell gap control function is distributed across three spacer components rather than relying on a single large spacer. The first spacer on the first substrate and the second spacer on the second substrate directly control local cell gap dimensions at pixel locations, enabling high pixel density. The third spacer provides additional gap control and ensures uniformity across the display area, compensating for the reduced size of individual spacers.
Solution Approach 2:
By adding the vertical dimension with the third spacer connecting both substrates, the system achieves cell gap control through a three-dimensional configuration. This allows the horizontal spacers (first and second) to be minimized for high pixel density while the vertical third spacer ensures uniform cell gap maintenance across the entire display area through its spanning structure.
Data Source
AI summary
According to one embodiment, a display device includes a first substrate including a first signal line and a second signal line adjacent to each other along a first direction, an organic insulating film located on the first signal line and the second signal line, and a first spacer located on the organic insulating film and a second substrate opposing the first substrate and including a second spacer opposing the first spacer. The organic insulating film has a through-hole between the first signal line and the second signal line in plan view. The first spacer is provided to overlap the through-hole in plan view and filling the through-hole.