Variable Aperture Seal Pattern for Liquid Crystal Display Gap Control
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Solution Overview
Problem
The One Drop Filling (ODF) method for liquid crystal display devices faces challenges in accurately controlling the gap between substrates due to fluctuations in liquid crystal dropping amount, leading to either excess liquid crystal leakage or insufficient filling, resulting in display defects.
Innovation Solution
The method involves creating a seal pattern with a variable area surrounded by the sealant, including a first and second seal frame, where the second seal frame has a smaller aperture ratio near the liquid crystal dropping position, and a capturing region to absorb surplus liquid crystals or voids, ensuring the panel volume aligns with the fluctuating liquid crystal amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the liquid crystal dropping amount is increased, then the gap between substrates is enlarged, but liquid crystal leakage occurs beyond the sealant
Solution Approach 1:
The seal pattern is divided into multiple segments (first seal frame and second seal frame) with varying aperture ratios. The second seal frame has a smaller aperture ratio near the liquid crystal dropping position to prevent leakage, while maintaining adequate gap width in other regions. This segmentation allows different parts of the seal pattern to serve different functions simultaneously.
Solution Approach 2:
The aperture ratio of the seal pattern is made non-uniform, with the second seal frame having a smaller aperture ratio specifically at the region near the liquid crystal dropping position. This local variation in quality prevents leakage at the critical dropping zone while maintaining overall gap width requirements elsewhere in the panel.
2Length of stationary object
If the liquid crystal dropping amount is decreased, then the gap between substrates is reduced, but voids are left causing display defects
Solution Approach 1:
The seal pattern is segmented into first and second seal frames with different aperture ratios. The first seal frame has a larger aperture ratio that ensures adequate gap width and prevents void formation, while the second seal frame with smaller aperture ratio controls leakage. This segmentation allows the system to tolerate dropping amount fluctuations without compromising display quality.
Solution Approach 2:
The aperture ratio parameter of the seal pattern is varied spatially, with the first seal frame having a larger aperture ratio to ensure sufficient gap width and prevent voids, while the second seal frame has a smaller aperture ratio to prevent leakage. This parameter change allows the system to maintain reliability across varying liquid crystal dropping amounts.
3Ease of manufacture
If a fixed seal pattern is used, then the manufacturing process is simple, but the gap width cannot be controlled accurately when liquid crystal dropping amount fluctuates
Solution Approach 1:
The seal pattern is segmented into first and second seal frames with different aperture ratios. This segmentation can be implemented using standard screen printing or dispenser techniques, maintaining ease of manufacture while achieving the dual functionality of gap control and leakage prevention through the varying aperture ratios.
Solution Approach 2:
The seal pattern incorporates local quality variations with different aperture ratios in different regions. The first seal frame has a larger aperture ratio for gap width control, while the second seal frame has a smaller aperture ratio for leakage prevention. These local variations can be achieved through conventional manufacturing techniques, balancing ease of manufacture with manufacturing precision.
Data Source
AI summary
Disclosed herein is a method of manufacturing a liquid crystal display device of dropping liquid crystals to be interposed between a first substrate and a second substrate to one of the substrates. The method includes a step of applying the sealant to one of the substrates where a region closed by the sealant is formed by a sealant on the main surface of the substrate, and, in this closed region, a liquid crystal filling region as a display region and a capturing region to the outer periphery of the liquid crystal filling region for intaking surplus liquid crystals or voids are formed.