Single-Substrate Display Device Microcavity Gas Discharge
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Solution Overview
Problem
Conventional liquid crystal displays (LCDs) require two substrates, leading to a heavy, thick, costly, and time-consuming manufacturing process, and struggle with gas accumulation in the organic layer affecting the aperture ratio.
Innovation Solution
A display device is designed using a single substrate with a microcavity structure, where a pixel electrode and common electrode are separated by a microcavity filled with a liquid crystal layer, and an insulating layer with exposed regions allows for gas discharge without affecting the aperture ratio, using a manufacturing method that does not require a separate mask for opening gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two substrates are used in conventional LCD manufacturing, then the structural integrity and display functionality are maintained, but the device weight, thickness, cost, and manufacturing time increase
Solution Approach 1:
The patent merges the opposing display panel functions into the TFT array panel by forming the common electrode, color filter, and light blocking members on the same substrate as the pixel electrodes. This integration eliminates the need for a separate opposing substrate, reducing device weight and thickness while maintaining display functionality through the microcavity structure that provides the necessary optical path and structural support
2Reliability
If two substrates are used in conventional LCD manufacturing, then the structural integrity and display functionality are maintained, but the manufacturing cost and process time increase
Solution Approach 1:
The patent combines multiple display components (pixel electrodes, common electrode, color filter, light blocking members) into a single substrate structure, reducing the number of manufacturing steps from two-substrate assembly to one-substrate processing. This integration significantly shortens process time and reduces manufacturing complexity while maintaining full display functionality
Solution Approach 2:
The single substrate in the patent serves multiple functions: it acts as the TFT array panel substrate, the opposing display panel substrate, and the structural support for the microcavity. This multi-functionality eliminates the need for separate opposing substrate manufacturing and assembly, improving productivity and reducing costs
3Illumination intensity
If the aperture ratio is increased to improve display quality, then the light transmission is enhanced, but gas accumulation in the organic layer occurs affecting the aperture ratio
Solution Approach 1:
The patent extracts gas accumulation issues from the sealed microcavity system by providing dedicated gas discharge paths through the insulating layer. These paths allow trapped gas to escape during and after organic layer formation, preventing gas bubbles from compromising the aperture ratio or display quality while maintaining high light transmission
4Object-affected harmful factors
If a separate mask is used for gas discharge opening, then the gas discharge path is created, but the manufacturing process complexity and cost increase
Solution Approach 1:
The patent merges the gas discharge opening formation with the existing insulating layer patterning process. The insulating layer is patterned to expose regions that serve dual purposes: as electrical insulation structures and as gas discharge pathways. This integration eliminates the need for separate mask steps while ensuring proper gas discharge functionality
Solution Approach 2:
The insulating layer in the patent serves multiple functions: electrical insulation, structural support, and gas discharge pathway. By making the insulating layer pattern serve as both the electrical insulation structure and the gas discharge opening definition, the patent eliminates the need for additional masking steps, reducing manufacturing complexity while ensuring effective gas discharge
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 reduces the weight, thickness, and cost of the display device while improving the aperture ratio and simplifying the manufacturing process by discharging accumulated gas without compromising the display quality.
Implementation Method 1
A voltage is applied to the field generating electrode to generate an electric field in the liquid crystal layer, which determines an orientation of liquid crystal molecules of the liquid crystal layer therethrough and controls polarization of incident light to display an image.
Data Source
AI summary
A display device includes a substrate including a plurality of pixel areas, a thin film transistor disposed on the substrate, a color filter and a light blocking member disposed on the thin film transistor, an insulating layer which is disposed on the color filter and the light blocking member and includes an exposed region through which the light blocking member is exposed, a pixel electrode which is disposed on the insulating layer and is connected to the thin film transistor through a contact hole, a common electrode which is spaced apart from the pixel electrode with a microcavity therebetween, a roof layer disposed on the common electrode, a liquid crystal layer which is filled in the microcavity, and an overcoat which is disposed on the roof layer and configured to seal the microcavity.