Microcavity Display Device Aperture Ratio and Robustness
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Solution Overview
Problem
Conventional liquid crystal displays using two substrates are heavy, thick, costly, and have long processing times, with limitations in aperture ratio and structural robustness.
Innovation Solution
A display device is designed using a single substrate with microcavities on a pixel electrode, covered by a roof layer and encapsulation, featuring injection holes for liquid crystal materials, which improves aperture ratio and structural strength by reducing the area of openings and injection holes, and allows for different liquid material layers in adjacent microcavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If two substrates are used in conventional liquid crystal displays, then the display can be assembled with traditional structure, but the device becomes heavy and thick
Solution Approach 1:
The patent merges multiple functional layers (pixel electrode, liquid crystal holding structure, encapsulation) onto a single substrate, eliminating the need for two separate substrates. This integration directly reduces device weight and thickness while maintaining all necessary display functions through the microcavity structure formed on the single substrate.
2Ease of manufacture
If two substrates are used in conventional liquid crystal displays, then the display can be assembled with traditional structure, but the manufacturing cost increases and process time lengthens
Solution Approach 1:
By combining multiple functions into a single substrate with integrated microcavities, the patent reduces the number of manufacturing steps required for assembling two separate substrates. This integration simplifies the production process, reduces material costs, and shortens overall manufacturing time while achieving the same display functionality.
3Ease of operation
If openings are made larger to facilitate liquid crystal injection, then injection is easier, but the aperture ratio decreases
Solution Approach 1:
The patent divides the liquid crystal injection process into multiple small injection holes distributed across the microcavity structure, rather than using one large opening. This segmentation allows sufficient liquid crystal to be injected through numerous small holes while maintaining a high aperture ratio, as the total area of small holes is much less than one large hole of equivalent total area.
Solution Approach 2:
The microcavity structure incorporates multiple porous injection holes that facilitate liquid crystal infiltration through capillary action and pressure differential, enabling effective injection through small openings without requiring large aperture openings that would reduce the display area.
4Quantity of substance
If injection holes are made larger to improve liquid crystal filling, then filling is more effective, but the structural strength decreases
Solution Approach 1:
The patent segments the injection system into multiple small holes rather than one or few large holes. This distribution of injection points ensures adequate liquid crystal filling throughout the microcavity while preserving the structural integrity of the microcavity walls, as the remaining material between small holes maintains structural strength.
Data Source
AI summary
The disclosure relates to a display device, and more particularly to a display device having an improved aperture ratio and robustness. The display device may provide a display device including: a substrate; a thin film transistor formed on the substrate; a pixel electrode connected to the thin film transistor; microcavities formed on the pixel electrode, the microcavities holding liquid crystals; a roof layer formed on the microcavities and covering some sides of the microcavities; and an encapsulation layer formed on the roof layer to seal the microcavities, wherein sides of neighboring microcavities define openings are disposed in a matrix configuration.