Spacer Size Control via Heat Treatment in Display Substrates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid crystal display (LCD) manufacturing processes face challenges in precisely controlling the size of spacers required for high-resolution displays, often necessitating complex halftone or slit mask processes.
Innovation Solution
The use of first and second spacers with different sizes, where the properties of the lower layers under the initial spacer pattern are varied through heat-treatment, allowing for precise control of spacer size without the need for halftone or slit mask processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If halftone or slit mask processes are used to control spacer size, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex halftone or slit mask processes from the manufacturing sequence. By using a simplified approach where spacer size is controlled through the properties of lower layers and heat treatment rather than complex masking, the process complexity is reduced while maintaining precision.
Solution Approach 2:
The patent changes the control parameter from mask-based geometric control to heat treatment-based material property control. By varying the properties of lower layers and applying heat treatment, spacer size is precisely controlled without requiring complex mask patterns, thus simplifying the manufacturing process.
2Manufacturing precision
If complex halftone or slit mask processes are applied, then spacer size precision is improved, but manufacturing time increases
Solution Approach 1:
The patent removes the time-consuming halftone or slit mask processes from the manufacturing sequence. The simplified approach using heat treatment and lower layer property variation achieves the same precision faster, reducing the overall manufacturing cycle time.
Solution Approach 2:
The patent performs preliminary preparation of lower layers with varying properties before the spacer formation step. This preliminary action eliminates the need for time-consuming mask processes during the actual spacer creation, thereby reducing manufacturing time while maintaining precision.
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
This approach enables the precise control of spacer sizes suitable for high-resolution displays, simplifying the manufacturing process and improving the uniformity of the liquid crystal layer thickness.
Implementation Method 1
heat-treating the initial spacer pattern
Data Source
AI summary
A display apparatus includes a first display substrate, a second display substrate which faces the first display substrate and is coupled to the first display substrate, first and second spacers disposed on one of the first and second display substrates, and a transparent electrode disposed between the one of the first and second display substrates and the first spacer.