Main and Sub-Column Spacer Alignment in LCD Color Filters
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Solution Overview
Problem
Current display devices face challenges in achieving high pattern accuracy and uniformity in the manufacturing of main and sub-column spacers, which are crucial for maintaining cell gap and preventing misalignment between substrates, particularly in liquid crystal display (LCD) devices.
Innovation Solution
The implementation of a display device design that includes a base substrate with a first color filter extending in a direction, multiple second color filters adjacent to the first filter, a passivation layer, and both main and sub-column spacers protruding from a light blocking portion, where the sub-column spacer is positioned between adjacent second color filters, and the main spacer overlaps the first color filter, with all spacers having the same material and thickness relative to the light blocking portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single column spacer structure is used, then the manufacturing process is simple, but the pattern accuracy and alignment precision are insufficient
Solution Approach 1:
The column spacer is divided into two distinct parts: a main column spacer and a sub-column spacer. The main column spacer is formed from the light blocking portion, while the sub-column spacer is formed separately and then coupled to the main column spacer. This segmentation allows each part to be optimized independently for its specific function, improving overall pattern accuracy while maintaining manufacturing feasibility.
Solution Approach 2:
The light blocking portion is formed first as the main column spacer, establishing the primary structure and position. Then, the sub-column spacer is formed and coupled to the main column spacer in a subsequent step. This preliminary action approach allows the main structure to be established before adding the refinement elements, ensuring proper alignment and pattern accuracy.
2Reliability
If different materials are used for main and sub-column spacers, then functional differentiation is achieved, but manufacturing complexity and process spread increase
Solution Approach 1:
Both the main column spacer and the sub-column spacer are formed using the same photosensitive material. This homogeneity in material composition simplifies the manufacturing process by using a single material system, reducing process complexity and minimizing process spread while still achieving the desired functional differentiation through structural design.
Solution Approach 2:
While using the same material, the spacer is segmented into main and sub-parts with different geometries and positions. The main column spacer has a larger cross-sectional area for structural support, while the sub-column spacer has a smaller cross-sectional area for precise alignment. This segmentation achieves functional differentiation through shape rather than material composition.
3Manufacturing precision
If the sub-column spacer overlaps the color filter, then the alignment is simplified, but the pattern accuracy and definition deteriorate
Solution Approach 1:
The sub-column spacer is designed with a localized position that does not overlap the color filter, creating a specific quality distinction in that region. This local quality approach allows the spacer to maintain its alignment function while avoiding the color filter area, thereby preserving pattern accuracy and definition in the color filter region.
Solution Approach 2:
Instead of achieving alignment through vertical overlap (one-dimensional approach), the sub-column spacer is positioned in a different spatial arrangement that is laterally offset from the color filter. This dimensional change allows the spacer to fulfill its alignment function while maintaining clear separation from the color filter, preserving pattern definition.
Data Source
AI summary
A display device includes a base substrate, a first color filter on the base substrate, the first color filter extending in a direction, a plurality of second color filters on the base substrate, the plurality of second color filters being adjacent to the first color filter, a passivation layer on the base substrate, the first color filter, and the plurality of second color filters, a light blocking portion on the passivation layer, a main column spacer protruding from the light blocking portion, and a sub-column spacer spaced apart from the main column spacer and protruding from the light blocking portion where the main column spacer overlaps the first color filter, and the sub-column spacer is disposed between two of the plurality of second color filters that are adjacent to each other.