Liquid crystal display element having a precisely controlled cell gap and method of making same

A liquid crystal display comprising:

• a first substrate, said first substrate comprising a major surface having disposed thereon a first plurality of display electrodes;
• a plurality of spacer members on said first substrate, said plurality of spacer members comprising a distribution of particles having a mean particle size and a plurality of smaller and larger particles relative to the mean particle sizes,
• wherein said substrate is subjected to an external energy source to preferentially remove a group of said plurality of particles, the majority of particles in said removed group being larger than the mean particle size;
• a second substrate having a major surface to said first substrate such that the major surface of said first substrate faces the major surface of said second substrate and said major surface of said first substrate cooperates with said major surface of said second substrate to contact and retain at least some of said plurality of spacer members therebetween, said at least some of said plurality of spacer members supporting said major surface of said first substrate and said major surface of said second substrate in a spaced apart configuration with a uniform gap therebetween;
• and
• a light influencing fluid material in said gap.

A light valve cell comprising:

• a first substrate comprising a major surface having disposed thereon a first plurality of display electrodes;
• a plurality of spacer members disposed on said first substrate, said plurality of spacer members comprising a group consisting of a plurality of particles having a nominal particle size and a plurality of larger and smaller particles relative to said nominal particle size, said group of particles comprising a non-gaussian distribution having a standard deviation above said nominal particle size that is less than the standard deviation below the nominal particle size;
• a second substrate having a major surface, said major surface having at least one display electrode disposed thereon, said second substrate being attached to said first substrate such that the major surface of said first substrate and the major surface of said second substrate contact and retain at least some of said plurality of spacer members therebetween, said at least some of said plurality of spacer members supporting said major surface of said first substrate away from said major surface of said second substrate in a spaced apart configuration with a uniform gap therebetween;
• and
• a liquid crystal material disposed in said gap.