Liquid Crystal Panel Spacer Adhesion via Color Filter Stacking
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Solution Overview
Problem
Conventional spacers used in high-resolution liquid crystal panels, such as those for head-mounted displays, tend to peel off easily when reduced in diameter, compromising the pixel aperture ratio and display quality.
Innovation Solution
A liquid crystal panel design featuring spacers composed of a stack of color filter layers with protrusion and continuous pattern portions, including a three-layer structure where the first and third color filters have protrusion patterns and the second color filter has a continuous pattern, enhancing adhesion and allowing for a higher pixel aperture ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the spacer diameter is reduced to increase resolution, then the pixel aperture ratio is improved, but the spacer peels off easily
Solution Approach 1:
The color filter layer is divided into multiple independent color filter regions (first, second, third color filters) that are stacked to form the spacer. Each color filter can be independently formed and positioned, allowing the spacer to maintain structural integrity even at reduced diameters while preventing peeling through the distributed multi-layer structure.
Solution Approach 2:
Multiple color filter layers are nested within each other to form the spacer structure. The first, second, and third color filters are stacked in sequence, with each layer contributing to the overall spacer formation. This nested arrangement creates a compact, peeling-resistant structure that maintains adhesion strength at smaller diameters.
2Measurement precision
If the spacer diameter is reduced, then the pixel aperture ratio is improved, but the manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The spacer formation process is segmented into multiple color filter deposition steps. Each color filter can be formed with standard manufacturing tolerances, and the cumulative effect of multiple layers achieves the required precision for high-resolution displays without demanding excessive precision from any single step.
Solution Approach 2:
The color filter layers serve dual functions: they provide the necessary color filtering for display quality and simultaneously form the spacer structure. This multi-functionality eliminates the need for separate spacer formation processes, simplifying manufacturing and maintaining precision across both functions.
3Ease of manufacture
If conventional photo spacers are used in isolated patterns, then the manufacturing process is simplified, but the spacers peel off easily when having smaller diameter
Solution Approach 1:
The multiple color filter layers are nested within each other in a systematic arrangement that provides both manufacturing simplicity and adhesion reliability. The first, second, and third color filters are positioned and stacked in a pattern that ensures overlapping adhesion zones, preventing peeling while maintaining ease of fabrication through the regular, repeating structure.
Data Source
AI summary
Provided is a liquid crystal panel with spacers tending not to peel off and with a high pixel aperture ratio. The liquid crystal panel includes a color filter substrate including a color filter layer and multiple spacers protruding toward a liquid crystal layer. The color filter layer includes at least a first-color filter and a second-color filter adjacent to the first-color filter in the row direction. The first-color filter includes a first continuous pattern portion disposed continuously to overlap a first subpixel group arranged in the column direction, and a first protrusion pattern portion protruding in the row direction from the first continuous pattern portion. The second-color filter includes a second continuous pattern portion disposed continuously to overlap a second subpixel group arranged in the column direction. The spacers each include a color filter stack including the first protrusion pattern portion and a part of the second continuous pattern portion.