Color Filter Aperture Control via Template Hollow Protrusions
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Solution Overview
Problem
Conventional methods for forming apertures in color filters face challenges in accurately controlling aperture size and area, leading to uncertainty and color deviation in transflective color filters.
Innovation Solution
A method involving a template with columnar hollow protrusions is used to form apertures in the pixel regions of color filters, where the template is bonded with a substrate, and the template is removed after heat treatment to create uniform apertures, allowing for precise control of aperture size and area through capillary stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If exposure and development processes are used to form apertures in the pixel resin layer, then the manufacturing process can be completed, but the aperture size and area cannot be accurately controlled
Solution Approach 1:
The template with columnar hollow protrusions is prepared in advance before the aperture formation process. The protrusions are pre-formed with precise dimensions (height of 3-8 μm and controlled cross-sectional areas) to define the exact aperture geometry. This preliminary preparation of the template structure eliminates the need for complex exposure and development processes, allowing direct formation of apertures with accurate size and area control through simple filling and removal steps.
2Reliability
If conventional mask etching is used to form apertures, then the process can be implemented, but the aperture area becomes uncertain leading to color deviation
Solution Approach 1:
The template acts as an intermediary tool that transfers the precise geometric information of the columnar hollow protrusions to the pixel resin layer. The template body with pre-formed protrusions serves as a master pattern that defines the exact aperture size and position. This intermediary structure ensures that the apertures formed by filling and removing the template have accurate and repeatable dimensions, eliminating the area uncertainty and color deviation associated with conventional mask etching methods.
3Illumination intensity
If apertures are formed to increase transmissivity and brightness, then the transmission performance improves, but the color saturation may be compromised
Solution Approach 1:
The template allows precise control of aperture parameters including size, shape, and distribution. By adjusting the dimensions of the columnar hollow protrusions (height, cross-sectional area, spacing), the aperture characteristics can be optimized to achieve the desired balance between brightness and color saturation. The uniformity of aperture size is ensured by the consistent geometry of the template protrusions, allowing reliable control over light transmission properties while maintaining color accuracy.
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 approach ensures accurate control over aperture size and area, addressing the issue of color deviation and uneven pore sizes, resulting in improved brightness and color saturation of color filters.
Implementation Method 1
flowing the pixel resin into hollow spaces of the columnar hollow protrusions under the effect of capillary stress
Data Source
AI summary
A manufacturing method and template of color filters belong to the field of liquid crystal display. The manufacturing method comprises: forming a black matrix (2) on a substrate (1), a pixel region being formed around the black matrix (2); forming pixel resin layers (3, 4, 5) on the substrate (1) on which the black matrix is formed; boxing the template with the substrate on which the pixel resin layers are formed, the template being located above the substrate (1), and a plurality of columnar hollow protrusions (13) being arranged at a part of a template body (12), corresponding to the pixel region, of the template; subjecting the boxed substrate to heat treatment, taking off the template so as to form a hole (11) in the pixel resin layer; and forming, through a patterning process, a pattern of the pixel resin layer on the substrate on which the hole (11) is provided. Therefore, the aperture and the opening area can be accurately controlled when providing an opening on the pixel region of the color filter.