Array Substrate Reducing Mask Count in IPS Display Manufacturing
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Solution Overview
Problem
Conventional in-plane switching (IPS) mode liquid crystal display manufacturing processes require five masks, making the process complex and inefficient.
Innovation Solution
The array substrate is manufactured using only two masks by forming a gate metal pattern, followed by sequential formation of a gate insulating layer, active layer, and data metal, then patterning to create data, source, and drain electrodes, simplifying the process and reducing mask usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If five masks are used to manufacture the array substrate, then the electrode structures can be formed, but the manufacturing process becomes complex and the number of masks increases
Solution Approach 1:
The patent combines multiple electrode formation steps into a single data metal layer that serves dual purposes: forming the data electrode and forming the pixel electrode. This merging of functions reduces the number of masks from five to three, simplifying the manufacturing process while maintaining the necessary electrode structures for IPS mode liquid crystal display operation
Solution Approach 2:
The data metal layer is designed to perform multiple functions simultaneously - it forms both the data electrode for applying data voltage and the pixel electrode for generating the horizontal electric field. This multi-functionality eliminates the need for separate metal layers and masks for each electrode type, directly addressing the contradiction between manufacturing simplicity and device complexity
Data Source
AI summary
A manufacturing method for an array substrate, comprising forming a gate metal on a base substrate, patterning the gate metal to form a gate part having a gate electrode, a gate line and a gate pad. Then, a gate insulating layer, an active layer and a data metal are sequentially formed on the base substrate to cover the gate part. The data metal is patterned to form a data part having a data electrode, a data pad and a pixel electrode. Then, the exposed portion of the active layer is removed, and the exposed portion of the gate insulation layer is removed. When the data electrode is divided into a source electrode and a drain electrode, a switching device is completed.