Black Matrix Light-Shielding Film Structure for Misalignment Control
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Solution Overview
Problem
Conventional liquid crystal display devices face challenges in achieving high contrast and preventing light leakage due to misalignment of light-shielding films, which affects display quality, especially in ultra-high-definition displays with small pixel pitches.
Innovation Solution
A substrate with a light-shielding film featuring a three-layer structure comprising a base film, a low-reflectance film, and a metal film, where the base film has a larger thickness than the low-reflectance and metal films, and the light-shielding film is designed with a lattice shape to overlap pixels and peripheral regions, effectively shielding light and reducing reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional light-shielding film structure is used, then the manufacturing process is simple, but light leakage occurs due to misalignment affecting display quality
Solution Approach 1:
The light-shielding film is segmented into three distinct layers: a base film, a low-reflection film, and a metal film. Each layer serves a specific function - the base film provides structural support, the low-reflection film reduces reflection, and the metal film provides light shielding. This segmentation allows the film to maintain reliability even with alignment shifts while managing the complexity through functional differentiation.
Solution Approach 2:
The invention uses a composite structure combining different materials with complementary properties: a polymer-based base film, a low-reflection coating material, and a metal layer. This composite approach enhances the overall performance by leveraging the strengths of each material - structural integrity from the base film, reflection reduction from the low-reflection layer, and light blocking from the metal film.
2Reliability
If the base film thickness is increased to improve light shielding, then light leakage is reduced, but manufacturing precision requirements increase
Solution Approach 1:
Instead of using a single thick base film that would require high manufacturing precision, the structure segments the light shielding function across three layers. The base film can be of moderate thickness since the combined effect of all three layers provides the light shielding, reducing the precision requirements for individual film thickness control.
Solution Approach 2:
Each layer is optimized for its specific function rather than requiring all layers to have uniform high thickness. The base film provides structural support, the low-reflection film is optimized for reflection reduction, and the metal film provides the primary light blocking. This local optimization allows moderate thickness control while achieving effective light shielding.
3Ease of manufacture
If a simple light-shielding film structure is used, then manufacturing is easier, but color filter formation precision is compromised
Solution Approach 1:
The three-layer light-shielding film structure is formed as a preliminary step before color filter formation. This preliminary structure provides a stable foundation that facilitates subsequent color filter deposition with high precision, as the layered structure offers good adhesion and a controlled surface for further processing.
Solution Approach 2:
The composite nature of the light-shielding film provides a multi-functional base that supports both easy manufacturing through standard deposition techniques and high-precision color filter formation. Each layer of the composite structure contributes to creating an optimal substrate for subsequent processing steps.
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 solution enhances display quality by effectively shielding light and preventing leakage, even with alignment shifts, and allows for precise formation of color filters, thereby maintaining high-quality displays in ultra-high-definition devices.
Implementation Method 1
a low-reflection film located between the base film and the metal film and having an optical reflectance lower than that of the metal film
Data Source
AI summary
Disclosed is a black-matrix substrate including a substrate, a light-shielding film located over the substrate and having a plurality of openings, and a plurality of color filters arranged in the plurality of openings. The light-shielding film includes a base film over the substrate, a metal film over the base film, and a low-reflectance film located between the base film and the metal film and has an optical reflectance lower than that of the metal film. The base film may include at least one of a resin and an inorganic compound.