Display with Spacer Ring

• US 20160170247A1
• Filed: 09/22/2015
• Published: 06/16/2016
• Est. Priority Date: 12/12/2014
• Status: Abandoned Application

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Hassan, Mohd Fadzli A., Lee, Myunghun, Yan, Jin, Gupta, Nathan K., Zhu, Xinyu, Yang, Young Cheol, Chen, Yu-Cheng
• Application Number:
  US14/862,004
• Publication Number:
  US 20160170247A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G02F 1/133334 Electromagnetic shields
• CPC Class Codes: G02F 1/133512 Light shielding layers, e.g. black matrix G02F1/136209 takes precedence
• CPC Class Codes: G02F 1/133514 Colour filters
• CPC Class Codes: G02F 1/1339 Gaskets; Spacers; Sealing of cells
• CPC Class Codes: G02F 1/13394 spacers regularly patterned on the cell subtrate, e.g. walls, pillars G02F1/133377 takes precedence
• CPC Class Codes: H01L 27/1259 Multistep manufacturing methods

Abstract

A display may have a layer of liquid crystal material interposed between a color filter layer and a thin-film transistor layer. A ring of adhesive sealant may surround the liquid crystal layer. Columns spacers may extend between the color filter and thin-film transistor layers through the liquid crystal layer to help ensure that the color filter and thin-film transistor layers are appropriately spaced apart from each other. A ring-shaped polymer spacer may surround the ring of adhesive sealant and may help protect display structures form exposure to etchant that is used to treat the edges of glass layers in the display. The spacer may be formed from the same layer of material that forms the column spacers. A black masking layer may be formed on the underside of the color filter layer using techniques that prevent the formation of protruding edge portions.

Claims

1. A display having a peripheral edge, comprising:

first and second display layers;

a ring of adhesive sealant that is interposed between the first and second display layers; and

a ring-shaped spacer that surrounds the ring of sealant and that runs along the peripheral edge of the display.

2. The display defined in claim 1, further comprising:

a layer of liquid crystal material between the first and second display layers, wherein the ring of adhesive sealant retains the liquid crystal material within the display between the first and second display layers.

3. The display defined in claim 2 wherein the first display layer comprises a color filter layer.

4. The display defined in claim 3 wherein the second display layer comprises a thin-film transistor layer.

5. The display defined in claim 4 further comprising column spacers on the color filter layer, wherein the ring-shaped spacer and the column spacers are formed from a common polymer layer.

6. The display defined in claim 5 wherein the polymer layer comprises a photoimageable polymer layer.

7. The display defined in claim 6 wherein the ring-shaped spacer is compressed between the color filter layer and the thin-film transistor layer and helps prevent liquid from reaching the ring of adhesive sealant.

8. The display defined in claim 7 further comprising a black masking layer on the color filter layer, wherein the color filter layer has a glass layer with an etched peripheral edge.

9. The display defined in claim 8 wherein the black masking layer comprises a black polymer layer having a peripheral edge that is aligned with the peripheral edge of the glass layer.

10. The display defined in claim 7 further comprising a metal layer having a peripheral edge that is aligned with the peripheral edge of the glass layer.

11. The display defined in claim 10 further comprising a dielectric layer that overlaps part of the metal layer and a black polymer layer that overlaps part of the dielectric layer.

12. A method for forming a liquid crystal display, comprising:

forming a display panel having a color filter layer, a thin-film transistor layer, a layer of liquid crystal material interposed between the color filter layer and the thin-film transistor layer, a ring of adhesive sealant that retains the liquid crystal material between the color filter layer and the thin-film transistor layer, and a polymer spacer having a ring shape that surrounds the ring of adhesive sealant;

grinding a peripheral edge of the color filter layer with a grinding tool; and

etching the peripheral edge of the color filter layer using an etchant, wherein the polymer spacer helps prevent the etchant from reaching the ring of adhesive sealant.

13. The method defined in claim 12 further comprising covering a thin-film transistor ledge region of the thin-film transistor layer during the etching.

14. The method defined in claim 13 wherein covering the thin-film transistor ledge portion comprises covering the thin-film transistor ledge region with a portion of the color filter layer.

15. The method defined in claim 14 further comprising removing the portion of the color filter layer that covered the thin-film transistor ledge region following the etching.

16. The method defined in claim 15 further comprising drilling at least one opening in the color filter layer before the etching.

17. The method defined in claim 16 further comprising simultaneously forming column spacers and the polymer spacer on the color filter layer using photolithography.

18. The method defined in claim 15 wherein removing the portion of the color filter layer that covered the thin-film transistor layer ledge region comprises using scribing and breaking techniques to remove the portion of the color filter layer.

19. A liquid crystal display, comprising:

a color filter layer having a glass substrate layer coated with a black masking layer;

a thin-film transistor layer having a glass substrate layer with thin-film transistor circuitry;

a layer of liquid crystal material interposed between the color filter layer and the thin-film transistor layer;

a ring of adhesive sealant that surrounds the layer of liquid crystal material and retains the liquid crystal material between the color filter layer and the thin-film transistor layer; and

a polymer spacer ring that surrounds the ring of adhesive sealant, wherein the ring of adhesive sealant is formed from a first material and the polymer spacer ring is formed from a second material that is different than the first material.

20. The liquid crystal display defined in claim 19 further comprising column spacers between the color filter layer and the thin-film transistor layer, wherein the column spacers are formed from the second material.

21. The with crystal display defined in claim 20 where in the first material is epoxy and wherein the second material is a photoimageable polymer.