Single-Substrate Display Device with Roof Layer and Adhesive Sealing
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Solution Overview
Problem
Conventional liquid crystal displays are heavy, costly, and have long processing times due to the use of two substrates, which can lead to contamination of the liquid crystal layer and peeling of the polarizer during the attachment process.
Innovation Solution
A display device is designed using a single substrate with a thin film transistor, pixel electrode, roof layer, liquid crystal layer, adhesive member, and polarizer, where the adhesive member is directly applied to the roof layer or insulating layer, reducing the need for an additional overcoat and stabilizing the polarizer attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two substrates are used to form the liquid crystal display, then the display device can be manufactured with conventional processes, but the weight, thickness, cost, and processing time increase
Solution Approach 1:
The patent merges two separate substrates into a single substrate structure. The liquid crystal layer is directly formed on the pixel electrode without requiring a separate opposing substrate, combining the functions of both substrates into one integrated structure. This reduces the overall weight and thickness while maintaining the liquid crystal display functionality.
Solution Approach 2:
The single substrate is designed to perform multiple functions that traditionally required two separate substrates. It serves as both the support structure and the electrode carrier, while also providing the sealing function through the adhesive member that seals the liquid crystal layer in place.
2Reliability
If an additional overcoat is formed to seal the liquid crystal layer, then the liquid crystal layer can be sealed, but the manufacturing cost increases and the process becomes more complex
Solution Approach 1:
The adhesive member simultaneously performs multiple functions: it seals the liquid crystal layer, provides structural support, and serves as the attachment surface for the polarizer. By combining these functions into a single component, the patent eliminates the need for a separate overcoat layer, simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The adhesive member is designed as a multi-functional component that replaces the traditional overcoat. It provides sealing, structural support, and polarizer attachment functions all in one layer, thereby reducing the number of manufacturing steps and material layers required.
3Ease of operation
If the polarizer is attached to the overcoat, then the polarizer can be positioned, but contamination of the liquid crystal layer and peeling of the polarizer occur
Solution Approach 1:
The patent extracts the polarizer attachment function from the overcoat layer and relocates it to the adhesive member. By taking the polarizer directly onto the adhesive member that is already bonded to the substrate, the process eliminates the risk of contaminating the liquid crystal layer during polarizer attachment, while also improving adhesion stability.
4Weight of moving object
If a single substrate is used to reduce weight and thickness, then the display device becomes lighter and thinner, but the risk of liquid crystal layer contamination and polarizer peeling increases
Solution Approach 1:
The adhesive member is designed as a multi-functional component that simultaneously seals the liquid crystal layer and provides a stable attachment surface for the polarizer. This multi-functionality ensures that even with a single substrate, the liquid crystal layer remains protected from contamination while the polarizer maintains stable adhesion.
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
This configuration reduces weight, thickness, and processing time while preventing liquid crystal layer contamination and polarizer peeling, simplifying the manufacturing process and reducing costs.
Implementation Method 1
an adhesive member formed on the roof layer and sealing the microcavities; and a first polarizer provided on the adhesive member
Data Source
AI summary
A display device for stably attaching a polarizer and preventing contamination of a liquid crystal layer includes: a substrate; a thin film transistor provided on the substrate; a pixel electrode connected to the thin film transistor; a roof layer disposed on the pixel electrode to be spaced apart from the pixel electrode with a plurality of microcavities therebetween; a liquid crystal layer for filling the microcavities; an adhesive member formed on the roof layer and sealing the microcavities; and a first polarizer provided on the adhesive member.