Spacer Patterned Substrate for Uniform Gap Without Diffraction
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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 affect durability and adhesive force, especially in curved or flexible configurations.
Innovation Solution
A substrate with a spacer pattern, including non-linear line spacers and bridges, is designed to maintain a stable gap between substrates while preventing optical defects, using a base layer with controlled spacer patterns.
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 spacer is divided into multiple segments (first spacer segment and second spacer segment) with different refractive indices. This segmentation allows each segment to serve a specific function: one segment maintains the gap while the other minimizes optical interference, thereby eliminating diffraction phenomena while maintaining uniform gap spacing.
Solution Approach 2:
Different portions of the spacer are assigned different refractive indices to perform different functions. The first spacer segment has a refractive index optimized for gap maintenance, while the second spacer segment has a refractive index optimized for optical performance. This local differentiation resolves the contradiction between mechanical function and optical performance.
2Object-affected harmful factors
If irregular arrangement of column spacers is used to avoid optical defects, then diffraction is reduced, but uniform gap maintenance becomes difficult
Solution Approach 1:
The spacer is segmented into multiple sections with different refractive indices arranged in a specific pattern. This structured segmentation maintains regular spacing for uniform gap control while the varying refractive indices prevent diffraction by avoiding simple periodic structures that cause optical interference.
3Manufacturing precision
If ball or column spacers are used, then gap maintenance is achieved, but durability and mechanical properties are poor
Solution Approach 1:
The spacer is constructed as a composite structure with multiple segments made of different materials having distinct refractive indices. This composite design enhances mechanical strength and durability while maintaining the gap function, overcoming the limitations of single-material ball or column spacers.
4Manufacturing precision
If ball or column spacers are used, then gap spacing is maintained, but adhesive force between substrates is insufficient
Solution Approach 1:
The spacer is divided into multiple segments that can be strategically positioned and bonded to both substrates. This segmentation increases the total bonding interface area and allows for optimized adhesive bonding at each segment-substrate interface, thereby enhancing overall adhesive force while maintaining precise gap spacing.
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.