Spacer-Pattern Substrate for Uniform Gaps and Diffraction Control
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Solution Overview
Problem
Existing optical devices face issues with optical defects such as diffraction phenomena and non-uniform gaps between substrates due to conventional spacers, which also compromise durability and adhesive force.
Innovation Solution
A substrate with a spacer pattern, including non-linear line spacers and partition spacers, is designed to maintain a stable gap between substrates while preventing optical defects, enhancing durability and adhesive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ball or column spacers are used, then the gap between substrates can be maintained, but optical defects such as diffraction phenomenon occur and uniformity is poor
Solution Approach 1:
The invention uses curved line spacers instead of straight line spacers. The curved shape of the spacers prevents diffraction phenomena and optical defects while maintaining uniform gap between substrates. The curvature radius is specifically designed to be 0.01 to 10 times the spacer width to optimize optical performance.
Solution Approach 2:
The invention employs asymmetric arrangement of line spacers where spacers are positioned at irregular intervals and orientations rather than symmetric patterns. This asymmetric configuration eliminates diffraction effects caused by regular periodic structures while maintaining effective gap control.
2Object-affected harmful factors
If irregular arrangement of column spacers is used, then optical defects are reduced, but uniform gap maintenance becomes difficult
Solution Approach 1:
The curved geometry of line spacers inherently prevents diffraction while the systematic curved pattern ensures uniform gap maintenance. The curvature radius optimization (0.01 to 10 times spacer width) balances optical performance with mechanical gap control.
3Manufacturing precision
If ball or column spacers are used, then gap maintenance is achieved, but durability and mechanical properties deteriorate
Solution Approach 1:
The invention uses thin film-based line spacers that can be integrated into the substrate structure. These flexible thin film spacers provide superior mechanical strength and durability compared to discrete ball or column spacers, while maintaining effective gap control through their extended linear geometry.
4Manufacturing precision
If ball or column spacers are used, then gap control is possible, but adhesive force between substrates is insufficient
Solution Approach 1:
The invention integrates line spacers directly into the substrate structure as a unified component rather than separate elements. This merging of spacer and substrate provides enhanced adhesive force through increased contact area and integrated bonding, eliminating the weak points associated with discrete spacer-substrate interfaces.
Data Source
AI summary
The present application provides a substrate comprising a spacer pattern. The present application can provide a substrate, which is applied to various optical devices, capable of evenly and stably maintaining a gap between substrates while maximally securing an active region without causing any optical defects, including a diffraction phenomenon, and the like. The present application can also provide an optical device comprising the substrate.