Non-linear Spacer Pad for Display Panel Alignment Stability
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Solution Overview
Problem
Conventional spacers in LCD panels, such as bead and photo spacers, cause light scattering and alignment deviations due to their random distribution and lack of secure attachment, leading to reduced display quality and yield.
Innovation Solution
A spacer structure with a non-linear spacer pad design that prevents relative motion between substrates by engaging the spacer in a zigzag or branched pattern, ensuring secure attachment and stability even under external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photo spacer is used to define precise pattern, then manufacturing precision is improved, but reliability deteriorates due to slipping under external force
Solution Approach 1:
The spacer structure is divided into two functional parts: the photo spacer (for precise pattern definition) and the spacer pad (for mechanical attachment). The spacer pad includes a non-linear structure with multiple contact points that engage with the substrate, providing stable mechanical anchoring while the photo spacer maintains precise geometric control through photolithography
Solution Approach 2:
The patent combines the photo spacer and spacer pad into a unified structure where the spacer pad is integrated with the photo spacer. The spacer pad's non-linear structure is formed as part of the same photolithography pattern, merging the precise patterning function with the mechanical attachment function in a single integrated component
2Ease of manufacture
If bead spacer is used to maintain cell gap, then ease of manufacture is improved, but display quality deteriorates due to light scattering
Solution Approach 1:
The patent extracts the harmful random distribution characteristic of bead spacers and replaces it with a precisely controlled pattern. The photo spacer's pattern is defined by photolithography, allowing complete removal of the random distribution problem while maintaining ease of manufacture through standard semiconductor fabrication processes
Solution Approach 2:
The spacer structure exhibits local quality through its patterned design, where the spacer material is present only in specific locations defined by the photolithography pattern. This localized presence eliminates light scattering in display regions while maintaining the cell gap function where needed
Data Source
AI summary
A spacer structure of a display panel includes a first substrate, a second substrate, a spacer, and a spacer pad. The spacer is disposed on a side of the first substrate facing the second substrate, and the spacer pad is disposed between the second substrate and the spacer. The spacer pad has a non-linear structure lodged in the spacer, and therefore restrains the spacer from moving with respect to the second substrate in the plane parallel to the surface of the second substrate.