Single-Substrate Display Device with Roof Layer Columns
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Solution Overview
Problem
Conventional liquid crystal displays require two substrates, leading to increased weight, cost, and manufacturing time due to the complexity of the structure.
Innovation Solution
A display device and manufacturing method utilizing a single substrate with a thin film transistor, pixel electrode, roof layer, and column structure that reduces weight, thickness, and processing time while maintaining rigidity, using a half-tone mask or slit mask to form the column without additional processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two substrates are used in conventional liquid crystal displays, then the display device can be manufactured with traditional structure, but the weight, thickness, cost and manufacturing time increase
Solution Approach 1:
The patent merges two separate substrates into a single substrate structure. The first substrate includes the thin film transistor array panel with pixel electrodes, while the second substrate (opposing display panel with common electrode) is integrated onto the same substrate, creating a single-substrate display device that eliminates the need for two separate substrates and reduces overall weight and complexity
Solution Approach 2:
The single substrate serves multiple functions that traditionally required two separate substrates. It simultaneously supports the thin film transistor array panel structure and the opposing display panel structure, including pixel electrodes, common electrode, color filters, and light blocking members, thereby reducing the number of components and manufacturing steps
2Device complexity
If two substrates are used in conventional liquid crystal displays, then the display device can be manufactured with traditional structure, but the manufacturing time and cost increase
Solution Approach 1:
The patent merges two separate substrates into a single substrate structure. The first substrate includes the thin film transistor array panel with pixel electrodes, while the second substrate (opposing display panel with common electrode) is integrated onto the same substrate, creating a single-substrate display device that eliminates the need for two separate substrates and reduces overall weight and complexity
Solution Approach 2:
The patent employs preliminary actions by forming the roof layer and column structures before final assembly steps. The roof layer is formed to define the space between pixel electrodes, and columns are preliminarily structured to maintain rigidity, allowing subsequent steps to proceed more efficiently without requiring rework or additional support structures
3Weight of stationary object
If one substrate is used to reduce weight and thickness, then manufacturing cost and time are reduced, but the rigidity and structural stability may be compromised
Solution Approach 1:
The patent segments the single substrate into distinct functional regions with specialized structures. The roof layer is segmented to cover specific areas between pixel electrodes, while columns are segmented at boundary portions of pixel areas to provide localized reinforcement. This segmentation allows the structure to maintain rigidity only where needed rather than requiring uniform thickness throughout
Solution Approach 2:
The patent applies local quality by providing structural reinforcement (columns) only at specific locations where rigidity is needed (boundary portions of pixel areas), rather than uniformly throughout the entire substrate. The roof layer is also selectively formed in specific regions to maintain space between electrodes, allowing the substrate to remain thin and lightweight in non-critical areas while maintaining strength where required
4Strength
If columns are added to maintain rigidity in single substrate structure, then structural stability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the column formation process with the roof layer formation process. Columns are formed by extending the roof layer material vertically at boundary portions of pixel areas, combining what could be separate manufacturing steps into a single integrated process, thereby reducing overall device complexity despite adding structural elements
Solution Approach 2:
The roof layer material serves multiple functions: it defines the space between pixel electrodes, provides structural support, and forms the columns for additional rigidity. This multi-functionality reduces the need for separate components, as the same material layer performs both spacing and reinforcement functions
Data Source
AI summary
A display device includes: a substrate including a plurality of pixel areas; a thin film transistor on the substrate; a pixel electrode connected to the thin film transistor; an roof layer connected between pixel areas adjacent in a first direction and separated from the pixel electrode; a column protruded from the roof layer in a boundary portion of the pixel areas; a space between the pixel electrode and the roof layer, the roof layer partially overlapping an upper inner wall and a first side inner wall of the space and exposing a second side inner wall of the space; a liquid crystal in the space.