Integrated Black Matrix COA for High-PPI LCD Alignment
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Solution Overview
Problem
As pixel density increases in LCDs, traditional methods face challenges in aligning layers, leading to issues like blurriness, imperfections, and increased thickness, which are exacerbated by the need for deeper holes for contact between layers.
Innovation Solution
Integrating a resin-based black matrix within the color filter array (COA) as a spacer and electrical connector, reducing the need for additional top layers and deeper holes, while improving alignment and reducing reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate black matrix layers are used, then sub-pixel partitioning is achieved, but layer alignment becomes difficult and thickness increases
Solution Approach 1:
The patent merges the black matrix function with the color filter array by integrating a resin black matrix directly into the COA structure. This eliminates the need for separate black matrix layers and reduces the number of manufacturing steps, thereby improving layer alignment precision while reducing overall LCD thickness.
Solution Approach 2:
The resin black matrix integrated in the COA serves multiple functions: it provides sub-pixel partitioning, acts as a spacer for maintaining layer spacing, and functions as an electrical connector. This multi-functionality reduces the need for additional layers and improves manufacturing alignment while keeping the structure compact.
2Measurement precision
If pixel density is increased, then display resolution is improved, but alignment difficulty and blurriness increase
Solution Approach 1:
By integrating the black matrix into the color filter array, the patent reduces the number of separate layers that need to be aligned. This merger simplifies the manufacturing process and maintains alignment accuracy even when pixel density is increased, preventing blurriness and imperfections.
Solution Approach 2:
The resin black matrix within the COA structure serves as a self-aligning element that automatically maintains proper positioning during manufacturing. This self-service capability ensures consistent alignment accuracy across different pixel densities without requiring additional complex alignment mechanisms.
3Reliability
If deeper holes are created for layer contact, then electrical connectivity is achieved, but manufacturing complexity and thickness increase
Solution Approach 1:
The resin black matrix is designed to serve as both a partitioning element and an electrical connector. By incorporating conductive materials or structures within the resin matrix, it provides electrical connectivity between layers without requiring deep holes, thereby reducing manufacturing complexity while maintaining reliable electrical connections.
4Manufacturing precision
If additional top layers are added for black matrix, then sub-pixel partitioning is achieved, but reflectivity and thickness increase
Solution Approach 1:
The patent eliminates additional top layers by merging the black matrix function into the color filter array. This integration reduces the number of interfaces between layers, thereby minimizing reflectivity issues while maintaining effective sub-pixel partitioning through the resin black matrix structure.
Data Source
AI summary
The disclosed liquid crystal display (LCD) backplane may include a bottom substrate dimensioned to display an array of pixels. The LCD backplane may also include a color filter array (COA) coupled to a top of the bottom substrate such that the COA enables a filtering of colors for the array of pixels. Additionally, the LCD backplane may include one or more black matrices coupled to the COA to partition sub-pixels of the array of pixels, wherein a black matrix is dimensioned as a spacer electrically connecting a layer on a proximal side of the COA and a layer on a distal side of the COA. Various other apparatuses, systems, and methods of manufacturing are also disclosed.