COA Substrate Manufacturing via Electric Chemical Deposition
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Solution Overview
Problem
The existing manufacturing methods for quantum dot color filters in display technology face challenges such as poor heat tolerance, toxicity, environmental pollution, and high costs due to the need for multiple photolithography processes, particularly in the COA substrate manufacturing process.
Innovation Solution
A method involving the use of PEDOT, PProDOT, or their derivatives with or without graphene, combined with electric chemical deposition to form quantum dot color filters on a TFT substrate, reducing the need for high-temperature processes and minimizing quantum dot usage, while utilizing modified quantum dots and scattering particles in electrolytic solutions to create red, green, and blue filter layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional photolithography process is used to manufacture quantum dot color filters, then color gamut and display quality can be improved, but manufacturing cost increases and environmental pollution occurs due to multiple processes and quantum dot waste
Solution Approach 1:
The patent extracts the quantum dot deposition step from the traditional multi-step photolithography process. By using electric field-assisted deposition, quantum dots are directly transferred from a donor substrate to the target substrate in a single step, eliminating the need for multiple photolithography cycles and reducing process complexity while maintaining color filter quality
Solution Approach 2:
The patent introduces an electric field as an intermediary mechanism to facilitate quantum dot transfer. The electric field acts as a mediator that enables precise deposition of quantum dots onto the substrate without requiring complex photolithography patterns, thus simplifying the manufacturing process
2Temperature
If quantum dot photoresist is used to reduce temperature during baking, then quantum dot integrity is preserved, but photoresist formulation becomes complex and requires extensive R&D
Solution Approach 1:
The patent replaces the thermal field (baking process) with an electric field for quantum dot deposition. Instead of using heat to drive the process, an electric field is applied to facilitate quantum dot transfer and formation, thereby avoiding the need for temperature control and complex photoresist formulations designed for low-temperature baking
3Manufacturing precision
If multiple photolithography processes are used to form color filters, then alignment precision can be achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent merges multiple photolithography processes into a single electric field-assisted deposition step. By combining the functions of pattern transfer, material deposition, and alignment into one process, manufacturing time is reduced while alignment precision is maintained through the precision of the electric field application
4Quantity of substance
If large quantities of quantum dots are used in photolithography process, then color filter coverage is sufficient, but waste and environmental pollution increase
Solution Approach 1:
The patent implements a quantum dot recovery mechanism where unused quantum dots from the donor substrate can be reused. The electric field-assisted deposition process allows for controlled transfer, minimizing waste and enabling the recovery and reuse of quantum dot material, thereby reducing environmental pollution and material costs
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
This method reduces waste, lowers production costs, and enhances environmental protection by minimizing quantum dot usage and eliminating the need for multiple photolithography processes, while improving the bonding strength of quantum dot films and reducing environmental impact.
Implementation Method 1
PEDOT (poly-3,4-ethylene dioxythiophene) and PProDOT (poly-3,4-propylene dioxythiophene) are 3,4-substituted polythiophenes, and are a class of conductive polymer material having high electrical conductivity, and being stable and transparent under oxidation state
Implementation Method 2
A method involving the use of PEDOT, PProDOT, or their derivatives with or without graphene, combined with electric chemical deposition to form quantum dot color filters on a TFT substrate
Data Source
AI summary
The disclosure provides a manufacturing method for COA substrate: utilizing PEDOT, PProDOT or PEDOT derivatives with or without doping with graphene, or PProDOT derivatives replaces traditional ITO to be conductive materials of pixel electrodes; quantum dots can be modified by ProDOT derivatives or EDOT derivatives which including carboxyl group, and quantum dot color filters of red filter layers, green filter layer and blue filters layers comprised on the TFT substrate are formed by the method of electric chemical deposition based on a property of the aforementioned two being able to polymerize under influences of electric field and pixel electrode patterns on the TFT substrate. Therefore, zero waste can be achieved in quantum dots, a usage of quantum dots can be decreased, indium usage can be decreased, researching and development cost can be reduced, and the circumstances can be protected, furthermore, the QDs color film having the better bonding strength bonds the counter electrode layer through chemical bond, and avoids adverse results as a peel is caused by insufficient bonding strength between photoresist and substrate.