Array Substrate Spacer Integration Reduces Photomask Count

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Solution Overview

Problem

The existing LCD panel fabrication process requires separate photomasks for forming spacers on the color filter substrate, increasing costs and complexity.

Innovation Solution

Integrating the spacer fabrication into the TFT array substrate process, using a first spacer as a mask to define the connecting layer and pixel electrode, thereby eliminating the need for additional photomasks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If spacers are formed on the color filter substrate using a separate photomask, then the spacing between substrates is maintained, but the fabrication cost increases and process complexity increases

Engineering Contradiction:

Improvespacing between substratesVSAvoidfabrication process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the spacer formation process with the TFT array substrate fabrication process. The spacer is formed as part of the same photomask pattern used for defining the pixel electrode and connecting layer, eliminating the need for a separate photomask and reducing process complexity while maintaining precise spacing control

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If spacers are formed on the color filter substrate using a separate photomask, then the spacing between substrates is maintained, but the fabrication cost increases

Engineering Contradiction:

Improvespacing between substratesVSAvoidfabrication cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the spacer formation with the pixel electrode and connecting layer definition in a single photomask step. This integration eliminates the need for an additional photomask and reduces the number of fabrication steps, thereby lowering manufacturing costs while maintaining precise spacer positioning

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the spacer fabrication is integrated into the TFT array substrate process, then the number of photomasks is reduced, but the aperture ratio must be maintained

Engineering Contradiction:

Improvenumber of photomasksVSAvoidaperture ratio

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The patent applies local quality by positioning the spacer only in specific regions where it is needed for maintaining substrate spacing, while keeping the pixel electrode and connecting layer definitions intact in other regions. This localized approach ensures the aperture ratio is maintained while still achieving spacer integration

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8872184B2Array structure and fabricating method thereof

Publication Date: 2014.10.28 AU OPTRONICS CORP

AI summary

An array structure, which includes a TFT, a passivation layer, a pixel electrode, a first connecting layer and a first spacer is provided. The TFT includes a gate, a source and a drain. The passivation layer overlays the TFT. The pixel electrode is located on the passivation layer. The first connecting layer is located on the pixel electrode and electrically connected to the pixel electrode and the drain. The first spacer is located on the first connecting layer.