Array Substrate Color Filter Formation for Display Yield
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Solution Overview
Problem
Conventional liquid crystal display elements face challenges in achieving high yield and uniform color filter layer formation due to the need for precise alignment between substrates, which can lead to color shift and uneven optical characteristics.
Innovation Solution
A display element design where the switching element layer is formed on the side of the light modulation layer opposite to the colored layer, allowing for a flat and stable colored layer formation, reducing the impact on the switching elements and improving yield by eliminating the need for high alignment accuracy between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a color filter layer is formed on a counter substrate, then color display is achieved, but high alignment accuracy between substrates is required which causes deterioration in yield
Solution Approach 1:
The patent inverts the conventional structure by forming the color filter layer on the array substrate instead of the counter substrate. This inversion eliminates the need for high alignment accuracy between substrates, as the color filter is now on the same substrate where the TFT layer is formed, thereby improving yield while maintaining color display quality
2Productivity
If a color filter layer is formed on a thin film transistor layer, then alignment accuracy requirement is reduced, but it is not easy to form a uniform film thickness and optical characteristics
Solution Approach 1:
The patent applies preliminary action by forming a flattening film on the TFT layer before forming the color filter layer. This preliminary flattening step creates a uniform surface that enables subsequent color filter deposition with consistent thickness and optical characteristics, resolving the manufacturing precision issue while maintaining high yield
3Device complexity
If a color filter layer is formed on a completed thin film transistor layer, then alignment accuracy is less critical, but the yield is greatly affected
Solution Approach 1:
The patent merges the color filter layer formation process with the TFT layer formation process by forming both layers on the same array substrate. This integration eliminates the need for separate substrate alignment operations, thereby improving yield while reducing device complexity related to alignment requirements
Data Source
AI summary
A thin film transistor layer including a thin film transistor is formed at a liquid crystal layer side of a color filter layer on an array substrate. Since it becomes possible to form the color filter layer at a position on a relatively flat glass substrate, satisfactory characteristics of the color filter layer can be obtained. The color filter layer is unlikely to have influence on the thin film transistor layer, so that the yield can be improved.