Array Substrate Black Matrix Alignment for Curved LCD Contrast
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Solution Overview
Problem
Curved liquid crystal displays (LCDs) face issues with light leakage and reduced contrast when displaying black images due to misalignment of the black matrix and driving circuits after bending, leading to increased luminance and decreased contrast.
Innovation Solution
The method involves manufacturing an array substrate with a black matrix and color filter layer disposed on the side of thin film transistors away from the substrate, ensuring orthographic projections of transistors are within the black matrix projections, and using higher reflectivity alignment marks to facilitate accurate patterning and alignment, preventing light leakage and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the black matrix and driving circuits are disposed on the array substrate, then the structure is compact, but after bending light leakage occurs and contrast decreases
Solution Approach 1:
The patent moves the black matrix and driving circuits from the front surface (2D plane) to the back surface of the array substrate, utilizing the third dimension (depth/thickness) to resolve the conflict between compactness and display quality. This spatial reconfiguration allows the front surface to be optimized for display while the back surface accommodates supporting structures.
Solution Approach 2:
Instead of placing the black matrix and driving circuits on the conventional front surface of the array substrate, the patent inverts the arrangement by positioning them on the back surface. This inversion eliminates the light leakage problem caused by misalignment after bending, as the driving circuits are no longer in the light path from the backlight to the display surface.
2Object-generated harmful factors
If alignment marks with low reflectivity are used, then the gate conductive layer has low reflectivity, but alignment precision during patterning decreases
Solution Approach 1:
The patent applies different reflectivity properties to different parts of the alignment mark structure. The gate conductive layer maintains low reflectivity overall, but the alignment mark regions have high reflectivity to provide clear alignment signals. This local differentiation allows both low overall reflectivity and high alignment precision to coexist.
Solution Approach 2:
The patent utilizes reflectivity contrast (optical property change) to create distinguishable alignment marks. The alignment marks are designed to have different reflectivity characteristics compared to the surrounding gate conductive layer, enabling precise optical detection and alignment during the patterning process while maintaining overall low reflectivity for display quality.
3Object-generated harmful factors
If the black matrix is positioned to cover transistor projections, then light leakage is prevented, but manufacturing alignment difficulty increases
Solution Approach 1:
The patent incorporates alignment marks in the bezel area before the black matrix patterning step. These pre-formed alignment marks serve as reference features that guide the subsequent black matrix alignment, making the manufacturing process easier by providing clear alignment targets rather than requiring direct alignment between complex transistor structures.
Solution Approach 2:
The alignment marks act as an intermediary element between the gate conductive layer and the black matrix. Instead of directly aligning the black matrix with the transistor structures (which is difficult), the alignment marks serve as a mediating reference that simplifies the alignment process and ensures accurate positioning.
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 enhances the display quality of curved LCDs by preventing light leakage and maintaining high contrast during black image display, improving the overall performance of curved display apparatuses.
Implementation Method 1
a reflectivity of the source-drain conductive layer is greater than a reflectivity of the gate conductive layer
Data Source
AI summary
A method of manufacturing an array substrate, includes: providing a substrate; forming a gate conductive layer including at least one first alignment mark; forming a source-drain conductive thin film; aligning a first mask and the substrate on which the gate conductive layer and the source-drain conductive thin film have been formed according to the at least one first alignment mark; patterning the source-drain conductive thin film by using the first mask to form at least one second alignment mark to obtain a source-drain conductive layer; forming a black matrix thin film; aligning a second mask and the substrate on which the gate conductive layer, the source-drain conductive layer and the black matrix thin film have been formed according to the at least one second alignment mark; patterning the black matrix thin film by using the second mask to form a black matrix; and forming a color filter layer.