Post Spacer Through-Holes for Liquid Crystal Filling
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Solution Overview
Problem
Conventional liquid crystal display apparatuses face delays in liquid crystal filling due to post spacers interrupting the flow, and issues with bubble formation and incomplete filling.
Innovation Solution
The display apparatus incorporates post spacers with through-holes of varying diameters and numbers, strategically positioned and oriented to facilitate smooth liquid crystal flow, reducing filling time and preventing bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional post spacers without through-holes are used to maintain constant gap between substrates, then substrate alignment and gap maintenance are improved, but liquid crystal filling time increases due to flow interruption
Solution Approach 1:
The post spacer is designed with through-holes penetrating its entire thickness, transforming it from a solid obstructive element into a porous structure that allows liquid crystal to flow through. This resolves the contradiction by maintaining the spacer's gap-maintaining function while eliminating flow interruption, thereby reducing filling time without sacrificing alignment precision.
Solution Approach 2:
The solid post spacer body is segmented into multiple through-holes, dividing the continuous material into a structured porous form. This segmentation allows liquid crystal to pass through multiple pathways simultaneously, reducing overall filling time while the outer structure of the spacer continues to provide mechanical support and gap maintenance.
2Strength
If post spacers are arranged in certain intervals to withstand external pressure, then structural support and substrate stability are improved, but liquid crystal flow is interrupted and filling efficiency decreases
Solution Approach 1:
By introducing through-holes into the post spacer structure, the spacer becomes a porous material that maintains mechanical strength for structural support while allowing liquid crystal to flow through its interior. This eliminates the trade-off between strength and filling efficiency, as the spacer now supports substrates and enables continuous liquid crystal flow simultaneously.
Solution Approach 2:
The post spacer exhibits local quality differentiation: the outer structure provides mechanical strength and structural support, while the interior through-holes facilitate liquid crystal flow. This local differentiation resolves the contradiction by assigning different functions to different regions of the same component, achieving both structural integrity and filling efficiency.
3Productivity
If uniform through-holes are provided in all post spacers, then liquid crystal flow is facilitated, but bubble formation may occur due to inconsistent flow distribution
Solution Approach 1:
The post spacers are designed with non-uniform through-hole configurations - those closer to the liquid crystal injection position have different through-hole characteristics (size, number, or arrangement) compared to those farther away. This local quality variation optimizes flow distribution across the panel, facilitating rapid filling while preventing bubble formation by ensuring consistent liquid crystal advancement throughout the display area.
Solution Approach 2:
Rather than applying uniform through-hole patterns to all post spacers, the invention employs asymmetric design where through-hole characteristics vary based on position relative to the injection point. This asymmetric configuration creates optimized flow paths that maintain high filling speed while distributing liquid crystal evenly to prevent bubble entrapment in different regions.
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 allows for faster and more even liquid crystal filling, preventing bubble issues and ensuring complete filling, thereby enhancing the efficiency of the liquid crystal filling process.
Implementation Method 1
a dipping method of dipping a liquid crystal filling inlet provided on one side of a liquid crystal panel into a liquid crystal material contained in a liquid crystal plate so that the liquid crystal may be filled into the panel using the capillary tube effect
Data Source
AI summary
A method of forming a plurality of post spacers between an upper substrate and lower substrate in a display apparatus comprises: applying a resin layer on an upper portion of the upper substrate or the lower substrate; arranging a plurality of through-hole forming bodies on an upper portion of the resin layer; applying a resin layer again on an upper portion of the resin layer where the plurality of through-hole forming bodies have been arranged; exposing the applied resin layer to light using a mask; removing areas other than areas where post spacers are to be formed from the applied resin layer; and removing the plurality of through-hole forming bodies from the areas where the post spacers are to be formed.