Liquid Crystal Cell Patterned Spacers Single Mask
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Solution Overview
Problem
The complexity and cost of producing liquid crystal cells are increased due to the need for multiple masks to develop spacers on opposite substrates, which complicates the manufacturing process.
Innovation Solution
A substrate structure with spacers where both substrates have spacers with the same shape and direction, intersecting at a preset angle, allowing for the use of a single mask to pattern the spacers, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are formed on both substrates using separate masks, then the spacers can be precisely positioned on each substrate, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the spacer patterning process for both substrates into a single mask step. The first and second spacers are formed simultaneously using one mask, eliminating the need for separate mask alignment and processing steps while maintaining precise positioning of both spacers relative to their respective substrates and to each other
Solution Approach 2:
The single mask serves multiple functions: it defines the pattern for both the first spacer on the first substrate and the second spacer on the second substrate simultaneously. This universal patterning approach replaces what would traditionally require two separate masks, reducing process complexity while achieving dual spacer formation with precise geometric control
2Manufacturing precision
If spacers are formed on both substrates using separate masks, then each spacer can be independently optimized, but the production cost increases
Solution Approach 1:
By combining the spacer formation into a single mask process, the patent reduces material costs (one mask instead of two), labor costs (fewer alignment and processing steps), and time costs (parallel formation of both spacers). The single mask approach maintains independent geometric control of both spacers while significantly lowering production costs
Solution Approach 2:
The patent discards the traditional approach of using separate masks for each substrate, recovering instead a single mask design that accomplishes both spacer patterning tasks. This eliminates redundant mask fabrication, storage, and handling costs while maintaining the ability to precisely control spacer geometries
Data Source
AI summary
A substrate with spacers and a liquid crystal cell containing the substrate are provided. The substrate includes a substrate; and a plurality of spacers arranged at a preset interval on one side of the substrate, the spacer has a cross section took in a direction parallel with the substrate, a size of the cross section of the spacer in a length direction is greater than a size thereof in a wide direction, and an angle between the length direction of the cross section of the spacer and an X-direction of the substrate is greater than 0° and less than 90°, or greater than 90° and less than 180°. Spacers on all the transparent substrates are manufactured using only one mask, thereby the cost of the production is reduced, the process of manufacturing the substrate is simplified, and the complexity of the process is reduced.