Substrate Spacer Layer Stack for Display Gap Control
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Solution Overview
Problem
Existing flat-type display devices face challenges in adjusting substrate spacing due to the increased number of steps required for providing spacers and the dependence on spacer size, which complicates the manufacturing process.
Innovation Solution
A display device configuration that includes a substrate spacing setting unit formed of two layers, a first adjustment layer patterned on the first substrate and a second adjustment layer stacked during the color filter formation, using the same material as the color filter, allowing for adjustable substrate spacing without the need for additional spacer formation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate spacer structure is provided to ensure substrate spacing, then substrate spacing can be maintained, but the number of manufacturing steps increases and substrate spacing adjustment becomes difficult
Solution Approach 1:
The invention merges the spacer function with the color filter layer by forming the color filter in a recessed portion of the spacer. This integration eliminates the need for a separate spacer structure, reducing manufacturing steps while maintaining substrate spacing control. The color filter material is deposited to fill the recessed portion, creating a multi-functional layer that serves both as a spacer and as a color filter.
Solution Approach 2:
The spacer structure is designed to perform multiple functions: it maintains substrate spacing and simultaneously serves as the color filter layer. By forming the color filter within the recessed portion of the spacer, the structure achieves multi-functionality, eliminating the need for separate components and simplifying the manufacturing process.
2Manufacturing precision
If substrate spacing is determined by spacer size, then spacing can be maintained, but adjusting substrate spacing becomes difficult
Solution Approach 1:
The invention enables dynamic adjustment of substrate spacing by controlling the depth of the recessed portion in the spacer. By varying the recessed portion depth, the substrate spacing can be precisely controlled and adjusted without changing the overall spacer dimensions. This provides adaptability in substrate spacing while maintaining structural integrity.
Solution Approach 2:
The substrate spacing is controlled by changing the geometric parameter of the recessed portion depth rather than the overall spacer size. This parameter change approach allows flexible adjustment of substrate spacing while maintaining the same spacer structure, improving adaptability without compromising manufacturing precision.
3Manufacturing precision
If gap materials are dispersed in sealing material to create spacers, then substrate spacing can be ensured, but the manufacturing process becomes more complex
Solution Approach 1:
The invention extracts the gap materials from the sealing material and places them specifically in the recessed portion of the spacer. This extraction approach allows the sealing material to maintain its primary sealing function while the recessed portion provides precise substrate spacing control. The gap materials are concentrated where needed rather than dispersed throughout the sealing material.
Data Source
AI summary
A display device of the present disclosure includes: a first substrate on which a pixel including a light emitting portion is formed; a second substrate arranged in a manner facing the first substrate; a color filter provided between the first substrate and the second substrate; and a substrate spacing setting unit provided in at least a peripheral portion of a display area of the first substrate made by forming pixels, and adapted to set substrate spacing between the first substrate and the second substrate. The substrate spacing setting unit is formed of at least two layers including: a first adjustment layer formed in a predetermined pattern on the first substrate; and a second adjustment layer stacked on the first adjustment layer in a step of forming the color filter by using a material same as a material of the color filter.