Black Column Spacer Manufacturing via Dual Organic Layers
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Solution Overview
Problem
Conventional methods for manufacturing black column spacers in display devices face challenges in achieving sufficient development margin and solvent resistance, leading to reliability issues and difficulties in maintaining uniform thickness and chemical resistance.
Innovation Solution
A method involving the formation of a first organic layer with high optical depth and a second organic layer with lower optical depth, using a half-tone mask for exposure and development, and curing, to create a black column spacer with improved reliability and development margin, incorporating a composition with binder resin, reactive unsaturated compounds, photopolymerization initiators, and pigments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single organic layer is used for black column spacer manufacturing, then the process is simple, but the development margin and solvent resistance are insufficient
Solution Approach 1:
The patent divides the single organic layer into two distinct organic layers: a first organic layer with high optical depth (OD≥1.0) containing black pigment for light blocking, and a second organic layer with lower optical depth containing fewer pigments. This segmentation allows each layer to perform specialized functions - the first layer provides optical depth and black matrix functionality, while the second layer provides solvent resistance and chemical stability, thereby resolving the contradiction between process simplicity and reliability.
Solution Approach 2:
The patent creates a composite structure by combining two different organic layers with different compositions and optical properties. The first organic layer uses a formulation optimized for optical depth with black pigments, while the second organic layer uses a formulation optimized for solvent resistance. This composite material approach allows the black column spacer to simultaneously achieve both high optical depth and excellent solvent resistance, overcoming the limitations of single-layer designs.
2Illumination intensity
If the optical depth of the black column spacer is increased to improve light blocking, then the black matrix performance is enhanced, but the development margin decreases
Solution Approach 1:
The patent segments the optical depth function from the development function by placing them in different layers. The first organic layer achieves high optical depth (OD≥1.0) through black pigment concentration, while the second organic layer with lower pigment content provides good development characteristics. This segmentation resolves the contradiction by allowing high optical depth without compromising development margin.
Solution Approach 2:
The patent applies local quality by giving different regions (layers) different optical depths and chemical compositions. The first organic layer has high optical depth for light blocking, while the second organic layer has lower optical depth and enhanced solvent resistance. This local differentiation allows each region to optimize its specific function without compromising the other.
3Ease of manufacture
If conventional black column spacer materials are used, then manufacturing is straightforward, but chemical resistance and reliability are compromised
Solution Approach 1:
The patent employs composite materials by formulating two different organic layers with distinct chemical compositions. The second organic layer specifically incorporates additives and formulations optimized for solvent resistance and chemical stability. This composite approach maintains manufacturing straightforwardness while significantly improving chemical resistance and reliability.
Solution Approach 2:
The patent changes the chemical parameters of the organic layers by adjusting composition, pigment concentration, and additive formulations. The second organic layer uses specific parameter adjustments (lower pigment content, optimized binder ratios) to enhance solvent resistance. These parameter changes resolve the contradiction between ease of manufacture and chemical resistance.
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
The method enhances the development margin and solvent resistance of the black column spacer, ensuring improved reliability and pattern stability while maintaining chemical resistance and reducing manufacturing costs.
Implementation Method 1
a photopolymerization initiator, a pigment, and a solvent. The first composition and the second composition may independently include about 1 wt % to about 30 wt % of a binder resin; about 1 wt % to about 20 wt % of a reactive unsaturated compound; about 0.05 wt % to about 5 wt % of a photopolymerization initiator
Data Source
AI summary
Disclosed are a method of manufacturing a black column spacer that includes preparing a substrate; forming a first organic layer on the substrate; forming a second organic layer on the first organic layer; performing exposure on the substrate on which the first organic layer and the second organic layer are formed using a half-tone mask; and developing the substrate and curing the resultant product, a black column spacer manufactured using the manufacturing method, and a color filter including the black column spacer.