Tunnel-Shaped Cavity Display Apparatus Manufacturing
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Solution Overview
Problem
The manufacturing process for flat-panel display apparatuses is complex and costly due to the need for separately manufacturing and aligning two differently structured substrates and using gap-defining spacers and adhesives.
Innovation Solution
A method involving a fluid-fillable tunnel structure within a single substrate, where a fluidic light controlling substance is filled into tunnel-shaped cavities defined between electrodes, eliminating the need for separate substrates and spacers, and using a sacrificial layer that can be removed with a microwave O2 plasma process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two differently structured substrates are separately manufactured and aligned with spacers, then the display apparatus can be assembled with proper gap spacing, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent merges the gap-defining spacer structure and the sealing structure into a single integrated structure. The spacer forms continuous peripheral walls that simultaneously define the gap spacing and seal the liquid crystal material, eliminating the need for separate spacer and sealing components. This integration directly reduces manufacturing process complexity while maintaining precise gap spacing control.
2Adaptability or versatility
If two substrates are separately manufactured and kept in inventory, then flexibility in manufacturing scheduling is improved, but inventory costs and manufacturing time increase
Solution Approach 1:
The patent combines multiple substrates into a single integrated substrate structure where the gap-defining walls are formed as part of the substrate itself. This eliminates the need to manufacture, store, and align separate substrates, thereby improving manufacturing efficiency while maintaining the flexibility to schedule production based on demand.
3Stability of the object's composition
If gap-defining spacers and adhesives are used to bond substrates, then proper gap maintenance and substrate bonding are achieved, but the number of materials and manufacturing steps increase
Solution Approach 1:
The patent merges the spacer material and sealing material into a single continuous peripheral wall structure. This integrated structure simultaneously maintains the gap spacing and seals the liquid crystal material, eliminating the need for separate adhesive materials and reducing the total quantity of materials required while maintaining structural stability.
4Ease of operation
If multiple separate components (substrates, spacers, adhesives) are used, then assembly flexibility is improved, but manufacturing cost increases
Solution Approach 1:
The patent integrates the gap-defining spacer and sealing functions into a single structure formed as part of the substrate. This reduces the number of separate components that need to be manufactured and assembled, thereby lowering manufacturing costs while maintaining the flexibility to adjust assembly processes.
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 simplifies the manufacturing process, reduces the number of substrates and liquid crystals needed, and significantly lowers manufacturing time and costs while maintaining display functionality.
Implementation Method 1
The sacrificial layer may include an organic material that can be selectively removed by a microwave O2 plasma process.
Data Source
AI summary
A display apparatus includes a plurality of pixel units and each pixel unit includes a substrate, a first electrode, a second electrode, an image display part and a protective layer. The first electrode is formed on the substrate. The second electrode is formed over the first electrode while interposing a first insulating layer therebetween to define a TSC (tunnel-shaped cavity) extending in a first direction between the first and second electrodes. The image display part is provided in the TSC to display an image according to an electric field generated by the first and second electrodes. The protective layer covers the second electrode and seals the TSC. The display apparatus having the above structure is manufactured by forming the first electrode, a sacrificial layer and the second electrode and forming the image display part by removing the sacrificial layer.