AlNi Alloy Data Lines for Corrosion-Resistant Display Panels
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Solution Overview
Problem
The manufacturing of larger liquid crystal display panels faces challenges due to signal transmission line delays and voltage loss caused by increased resistance, which is exacerbated by the need for additional processes to prevent corrosion in low-resistance lines, leading to higher costs and complexity.
Innovation Solution
The use of aluminum alloy containing nickel for data, source, and drain electrodes, along with a conductive layer of molybdenum, titanium, or tantalum, reduces reactivity with ions, allowing for simplified manufacturing processes by omitting residue ion removal steps and enhancing corrosion resistance, thereby reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If materials having low resistance are applied to the signal transmission lines to reduce resistance, then electrical conductivity is improved, but device complexity increases due to additional mass production processes needed to prevent corrosion
Solution Approach 1:
The patent applies composite materials by using an aluminum-based alloy containing nickel (and optionally lanthanum or boron) for the data line, source electrode, and drain electrode. This composite material combines the low resistance properties of aluminum with the corrosion resistance of nickel and other additives, achieving both electrical conductivity and corrosion resistance without requiring additional protective processes.
Solution Approach 2:
The patent changes the material parameters by specifying precise compositional ranges: aluminum-based alloy containing nickel (3-13 atomic%), and optionally lanthanum (0.1-5 atomic%) or boron (0.1-5 atomic%). By optimizing these material parameters, the alloy achieves both low resistance and high corrosion resistance, eliminating the need for additional corrosion prevention processes.
2Reliability
If additional processes are added to prevent corrosion of low-resistance signal transmission lines, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The aluminum-based alloy with nickel and optional lanthanum or boron provides inherent corrosion resistance through its compositional design. The nickel content (3-13 atomic%) forms a protective layer that prevents corrosion, while the optional lanthanum or boron further enhances this property. This eliminates the need for additional corrosion prevention processes such as plating or coating, thereby reducing manufacturing cost.
Solution Approach 2:
The alloy material itself provides the corrosion resistance function through its inherent compositional properties. The nickel and optional lanthanum or boron in the aluminum-based alloy create a self-protecting structure that resists corrosion without requiring external protective layers or additional processing steps, making the material self-sufficient for corrosion protection.
3Reliability
If additional processes are added to prevent corrosion of signal transmission lines, then corrosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The aluminum-based alloy with nickel (3-13 atomic%) and optional lanthanum (0.1-5 atomic%) or boron (0.1-5 atomic%) provides inherent corrosion resistance through its compositional design. This composite material structure eliminates the need for additional corrosion prevention processes such as plating, coating, or special handling procedures, thereby simplifying the manufacturing process.
Solution Approach 2:
The alloy material provides self-corrosion resistance through its inherent compositional properties. The nickel and optional lanthanum or boron create a self-protecting structure that resists corrosion without requiring external protective layers or additional processing steps, reducing manufacturing process complexity.
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 results in improved corrosion resistance and reduced manufacturing complexity, enabling the production of larger liquid crystal display panels with lower costs and fewer process steps, while maintaining effective signal transmission.
Implementation Method 1
reduces reactivity with ions, allowing for simplified manufacturing processes by omitting residue ion removal steps
Implementation Method 2
The conductive layer includes at least one of molybdenum, titanium, and tantalum. The conductive layer makes contact with a semiconductor pattern arranged under the source electrode and the drain electrode.
Data Source
AI summary
In a display panel and a method of manufacturing the display panel, a gate line, a data line, and source and drain electrodes including a same material as the data line are formed on a substrate constituting the display panel, and the data line includes an aluminum based alloy containing sufficient nickel to inhibit corrosion during dry etching. The corrosion resistance of the AlNi-containing alloy helps prevent corrosion of the data line, the source electrode, and the drain electrode during selective dry etching that shapes these lines and electrodes.