Overlapping LCD Panels with Integrated Spacer Insulator
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Solution Overview
Problem
The manufacturing process of liquid crystal display devices with overlapping display panels is complex and costly, doubling the process compared to single-panel devices, leading to increased manufacturing expenses.
Innovation Solution
A liquid crystal display device design featuring two overlapping display panels, where the second display panel includes a first substrate with a source line, gate line, thin film transistor, and organic insulator, and a second substrate opposite the first substrate with a liquid crystal layer in between, utilizing spacers made of positive photosensitive resin to maintain distance, and integrating the spacers with the organic insulator for simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If two display panels are used to overlap each other to improve contrast, then the contrast is improved, but the manufacturing process becomes about double and manufacturing cost increases
Solution Approach 1:
The patent merges the spacer formation process with the organic insulator formation process by using the same positive photosensitive resin material for both. This integration allows both structures to be formed simultaneously through a single coating and exposure process, eliminating the need for separate spacer formation steps and reducing manufacturing complexity while maintaining the dual-panel contrast improvement capability
2Illumination intensity
If two display panels are used to overlap each other to improve contrast, then the contrast is improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into a single material layer. The positive photosensitive resin serves dual purposes as both the organic insulator and the spacer material. This merging reduces material costs and process costs by eliminating redundant steps and materials that would be required if separate processes were used for forming spacers and organic insulators
Solution Approach 2:
The positive photosensitive resin performs multiple functions: it acts as the organic insulator layer, forms the spacer structures, and provides electrical insulation. This multi-functionality reduces the overall manufacturing complexity and cost by eliminating the need for separate materials and processes for each function
3Manufacturing precision
If spacers are formed separately from the organic insulator, then the spacer distance can be controlled, but the manufacturing process becomes more complex
Solution Approach 1:
The patent forms both the organic insulator and spacers from the same positive photosensitive resin layer through a single coating and exposure process. The spacer height is controlled by the thickness of the resin layer and exposure parameters, achieving precise distance control while simplifying the manufacturing process by eliminating separate spacer formation steps
4Adaptability or versatility
If separate materials are used for spacers and organic insulator, then each component can be optimized independently, but the manufacturing process and cost increase
Solution Approach 1:
The patent uses the same positive photosensitive resin for both the organic insulator and spacer components, integrating their formation into a single process step. This approach prioritizes manufacturing simplicity and cost reduction while still achieving the required functional optimization through careful selection of the resin's properties and exposure parameters
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the manufacturing process of liquid crystal display devices with overlapping panels, reducing costs by integrating spacers with the organic insulator and using positive photosensitive resin, thereby improving manufacturing efficiency and reducing expenses.
Implementation Method 1
a first spacer is formed in the first substrate to hold a distance between the first substrate and the second substrate. The first spacer and the organic insulator are made of a positive photosensitive resin
Data Source
AI summary
A liquid crystal display device in which a plurality of display panels are disposed so as to overlap each other and which displays an image on each of the plurality of display panels. The liquid crystal display device includes a first display panel; and a second display panel disposed so as to overlap the first display panel. The second display panel includes a first substrate on which a source line, a gate line, a thin film transistor, and an organic insulator are formed, a second substrate disposed opposite to the first substrate, and a liquid crystal layer disposed between the first substrate and the second substrate, a first spacer is formed in the first substrate to hold a distance between the first substrate and the second substrate. The first spacer and the organic insulator are made of a positive photosensitive resin.