Array Substrate Flat Layer Formation via Unified Photoresist Coating
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Solution Overview
Problem
The manufacturing process of array substrates and color filter substrates is complex and inefficient due to the need for forming a flat layer on each color-resist and control electrode surface separately, increasing production time and reducing efficiency.
Innovation Solution
A method where control electrodes and color-resists are formed on a shared baseplate, with a transparent photoresist coating to create a flat layer that covers all color-resists, eliminating the need for separate formation of the fourth color-resist and simplifying the manufacturing procedure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flat layer is formed separately on each color-resist and control electrode surface, then the protection and flattening function is achieved, but the manufacturing procedure becomes complicated and production efficiency is reduced
Solution Approach 1:
The patent merges the formation of the flat layer into a single unified process that simultaneously covers both the color-resist regions and control electrode regions. Instead of performing separate coating operations for each region, the invention applies the flat layer material once across the entire surface, reducing the number of manufacturing steps while maintaining the protective and flattening functions.
Solution Approach 2:
The flat layer is designed to serve multiple functions simultaneously: it protects both the color-resist and control electrodes, provides a flat surface for subsequent layers, and acts as an insulating layer. This multi-functional approach eliminates the need for separate protective layers for different regions, simplifying the manufacturing process.
2Manufacturing precision
If the flat layer is formed on both color filter substrate and array substrate separately, then complete coverage is achieved, but the manufacturing procedure increases and production efficiency is reduced
Solution Approach 1:
The patent combines the flat layer formation steps for both the color filter substrate and array substrate into a single integrated process. By coordinating the manufacturing sequences, the flat layer is formed in one operation rather than through two separate procedures, reducing process complexity while ensuring complete coverage of all required surfaces.
3Measurement precision
If multiple separate procedures are used to form the flat layer on different regions, then precise positioning is achieved, but the production efficiency is reduced
Solution Approach 1:
The patent incorporates positioning marks and alignment structures into the substrate before the flat layer formation process. These pre-established reference features enable precise positioning to be achieved in a single coating operation, eliminating the need for multiple sequential procedures while maintaining high positioning accuracy.
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 reduces production costs, improves alignment accuracy, and enhances light transmissivity, leading to increased brightness and efficiency in the production of array substrates.
Implementation Method 1
coating the baseplate on which the control electrodes, the first color-resist, the second color-resist, and the third color-resist are formed and the fourth color-resist region with a transparent photoresist so as to form a flat layer
Data Source
AI summary
A method for manufacturing an array substrate and an array substrate are disclosed. The method comprises the steps of forming a plurality of control electrodes on a baseplate, and forming a color-resist region between two adjacent control electrodes, wherein the color-resist region is a first color-resist region, a second color-resist region, a third color-resist region, and a fourth color-resist region in sequence; forming a first color-resist in the first color-resist region, forming a second color-resist in the second color-resist region, and forming a third color-resist in the third color-resist region; and coating the baseplate on which the control electrodes, the first color-resist, the second color-resist, and the third color-resist are formed and the fourth color-resist region with a transparent photoresist so as to form a flat layer. In the method according to the present disclosure, the production efficiency of the array substrate can be improved.