Microcavity Display Encapsulation Layer
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Solution Overview
Problem
Conventional liquid crystal displays (LCDs) face issues with weight, thickness, manufacturing costs, and process time due to the use of two substrates, and there is a risk of defects from contact between the color filter, light blocking member, and liquid crystal layer caused by level differences.
Innovation Solution
A display device and manufacturing method using a single substrate with microcavities and an encapsulation layer to prevent contact between the liquid crystal layer and the color filter and light blocking member, reducing weight, thickness, and manufacturing time, while improving reliability by forming these layers on the encapsulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two substrates are used to form the display device, then the color filter and light blocking member can be formed on one substrate and the liquid crystal layer on the other, but the device weight and thickness increase
Solution Approach 1:
The patent merges the color filter layer and light blocking member layer onto the same substrate as the liquid crystal layer, eliminating the need for a separate opposing substrate. This integration reduces the overall device weight and thickness while maintaining the functional separation of layers through the encapsulation layer barrier.
2Weight of stationary object
If the color filter and light blocking member are formed on the same substrate as the liquid crystal layer, then weight and thickness are reduced, but contact between layers may occur causing defects
Solution Approach 1:
The patent introduces an encapsulation layer as an intermediary barrier between the organic layers (color filter and light blocking member) and the liquid crystal layer. This encapsulation layer prevents direct contact between the layers, eliminating the risk of defects caused by layer contact while allowing all layers to be formed on a single substrate.
3Reliability
If conventional two-substrate manufacturing is used, then layer contact can be prevented, but manufacturing cost and process time increase
Solution Approach 1:
The patent combines multiple layers (color filter, light blocking member, and liquid crystal layer) into a single substrate structure, reducing the number of manufacturing steps required. This merging of layers eliminates the need for separate substrate assembly processes, thereby reducing manufacturing time and costs while maintaining reliability through the encapsulation layer.
Data Source
AI summary
A display device and a method of manufacturing the display device improve reliability by preventing contact between a color filter, a light blocking member and a liquid crystal layer. The display device includes: a substrate including pixel areas; a thin film transistor formed on the substrate; a pixel electrode connected to the thin film transistor and formed in the pixel areas; a roof layer formed on the pixel electrode; microcavities interposed between the pixel electrode and the roof layer; an injection hole formed in the roof layer, the injection hole configured to expose at least a portion of the microcavities; a liquid crystal layer filled in at least one of the microcavities; an encapsulation layer formed on the roof layer, the encapsulation layer configured to cover the injection hole and to seal the microcavities; and an organic layer formed on the encapsulation layer.