Slanted Organic Layer Reduces Weight and Thickness in Display Devices
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Solution Overview
Problem
Conventional liquid crystal display devices are heavy, thick, and costly due to their complex structure requiring two panels and multiple constituent elements, which also leads to longer manufacturing times.
Innovation Solution
A display device with a substrate, pixel electrode, common electrode, and an organic layer where the organic layer's surface is slanted with respect to the substrate, forming a robust structure that minimizes the need for additional support components, and a manufacturing method that uses a mask with transmissive portions to pattern the organic layer, reducing weight, thickness, and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional liquid crystal display device uses two panels and multiple constituent elements, then the display function is achieved, but the device becomes heavy, thick, and costly with longer manufacturing time
Solution Approach 1:
The patent merges the functions of two separate panels into a single panel structure. The first panel includes a substrate, pixel electrode, common electrode, and organic layer, while the second panel is integrated such that the organic layer of the first panel and the common electrode of the second panel are positioned adjacent to each other, eliminating the need for separate panel assemblies and reducing overall device complexity
Solution Approach 2:
The organic layer serves multiple functions: it acts as a protective layer, a sealing structure, and an optical element. The slanted configuration of the organic layer provides both structural support and pressure distribution, while also serving as part of the liquid crystal containment structure, thereby reducing the number of separate components needed
2Reliability
If a conventional liquid crystal display device uses two panels and multiple constituent elements, then the display function is achieved, but the device becomes heavy and thick
Solution Approach 1:
The patent combines multiple functional layers into integrated structures. The organic layer is positioned to serve as both a protective barrier and a structural support element, eliminating the need for separate reinforcement components and reducing overall device weight
Solution Approach 2:
The organic layer is configured as a thin film with a slanted surface that provides structural support. This thin film structure replaces heavier rigid support components while maintaining the necessary mechanical strength and pressure distribution capabilities
3Reliability
If a conventional liquid crystal display device uses two panels and multiple constituent elements, then the display function is achieved, but the manufacturing time increases
Solution Approach 1:
The patent merges the manufacturing processes of two separate panels into a single integrated process. The organic layer is formed in a single step that simultaneously creates the protective structure, sealing element, and optical component, thereby reducing the total number of manufacturing steps and time required
Solution Approach 2:
The organic layer is formed with its slanted configuration during the manufacturing process itself, rather than requiring subsequent assembly or adjustment steps. This preliminary formation of the structural configuration eliminates additional manufacturing time that would be required for post-processing
4Ease of manufacture
If the organic layer has a flat structure, then the manufacturing is simple, but the structure cannot effectively withstand pressure
Solution Approach 1:
The organic layer is configured with a slanted surface rather than a flat plane. This angled configuration creates a more robust structure that can effectively distribute and withstand external pressure while maintaining manufacturing simplicity through a single forming step
5Strength
If additional enforcement or protection parts are added, then the structure can withstand pressure, but the manufacturing cost and time increase
Solution Approach 1:
The organic layer is designed to serve multiple functions simultaneously: it provides pressure resistance, acts as a protective barrier, serves as a sealing structure, and functions as an optical element. This multi-functionality eliminates the need for separate enforcement or protection parts, thereby reducing device complexity and manufacturing cost
Data Source
AI summary
Provided are a display device capable of reducing a weight, a thickness, a cost, and a process time and having a durable structure, and a manufacturing method thereof. The display device includes: a substrate including a plurality of pixel areas; a thin film transistor formed on substrate; a first electrode connected to the thin film transistor to be formed in the pixel area; an organic layer formed on the first electrode so as to be connected along the adjacent pixel areas in a first direction among the pixel areas; a space positioned on the first electrode, of which parts of the upper surface and the side are surrounded by the organic layer; a liquid crystal formed to fill the space; and an overcoat formed to cover the rest side of the space which is not covered by the organic layer, in which a height of the upper surface of the organic layer is gradually lowered toward both edges of the pixel area from the center of the pixel area.