Color Conversion Panel Alignment Patterns for Stitch Error Control
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Solution Overview
Problem
The increase in mask size for exposing large color conversion panels leads to higher manufacturing costs, and stitch errors during multiple exposure processes result in deteriorated electrical characteristics and visible stitch stains.
Innovation Solution
Incorporation of alignment patterns and opening patterns in the color conversion panel design allows for monitoring and minimizing stitch errors, ensuring similar heights of color filter layers and preventing fringing phenomena.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the color conversion panel size is increased, then the display area is improved, but the mask size increases leading to higher manufacturing costs
Solution Approach 1:
The color conversion panel is divided into multiple shot areas that can be exposed separately using smaller masks. The panel includes first shot areas and second shot areas with boundary regions between them, allowing the manufacturing process to use cost-effective smaller masks while maintaining large overall panel area.
2Ease of manufacture
If multiple exposure processes are used to divide the color conversion panel, then manufacturing cost is reduced, but stitch errors occur at the boundary between shot areas
Solution Approach 1:
Alignment patterns are pre-formed in the boundary regions between shot areas before the exposure processes. These alignment patterns include reference marks that enable precise alignment between adjacent shot areas during the exposure process, preventing stitch errors at the boundaries.
Solution Approach 2:
The patent replaces mechanical alignment methods with optical alignment using alignment patterns and reference marks that can be detected and measured optically. This allows for sub-pixel level alignment precision between shot areas, significantly improving manufacturing precision compared to traditional mechanical alignment.
3Reliability
If stitch errors occur at the boundary between shot areas, then electrical characteristics deteriorate and stitch stains become visible, but alignment monitoring is needed
Solution Approach 1:
The patent implements a feedback mechanism where alignment patterns and reference marks are used to monitor and measure stitch errors in real-time during the manufacturing process. This feedback allows for immediate detection and correction of alignment issues, preventing deterioration of electrical characteristics and formation of visible stitch stains.
Data Source
AI summary
A color conversion panel includes a substrate including a display area including a color conversion layer, a first pixel area, a second pixel area, and a non-pixel area, and a plurality of color filter layers on the substrate. The color filter layers include a first color filter layer in the first pixel area and defining in the non-pixel area, a first alignment pattern, and a first opening spaced from the first alignment pattern, the first pixel area and the second pixel area, and a second color filter layer in the second pixel area, covering the first alignment pattern of the first color filter layer and defining in the non-pixel area a second alignment pattern which overlaps the first opening of the first color filter layer and exposes a portion of the first color filter layer at the first opening, to outside the second color filter layer.