Color Filter with Integral Black Matrix and Ink Jet Printed Layer

Solution Overview

Problem

The existing manufacturing methods for liquid crystal display color filters face challenges in achieving the required thickness between substrates due to limitations in spacer height, leading to uneven thickness and increased defect rates, as conventional materials used for spacers have restricted height ranges.

Innovation Solution

The method involves forming a black matrix and spacers integrally on a substrate using a black film, where the color filter layer is created using ink jet printing, allowing for a thickness difference that satisfies the spacer height requirement, enabling the use of conventional materials and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional materials are used for black matrix and spacers with integral formation, then manufacturing process is simplified, but spacer height is limited to 0.2-0.6 um which is insufficient for required 3-4 um liquid crystal layer thickness

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidspacer height

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The invention separates the formation process into two stages: first forming the black matrix and spacer structure integrally, then selectively removing portions of the black matrix to create color resistance regions. This segmentation allows the spacer to achieve greater height than conventional integral formation while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The black matrix and spacers are formed in advance as an integral structure, establishing the basic framework before the color filter layer is applied. This preliminary action enables the spacer height to exceed conventional limits while keeping the manufacturing process efficient.

Inventive Principle:

Principle #10Preliminary action

2Length of stationary object

If black film thickness is increased to achieve required spacer height, then space between substrates increases to 3-4 um, but thickness uniformity deteriorates due to energy differences in exposure machines

Engineering Contradiction:

Improvespace between substratesVSAvoidblack film thickness uniformity

Core Design Contradiction:

Length of stationary objectVSManufacturing precision

Solution Approach 1:

The black matrix and spacers are formed in advance as an integral structure, establishing the basic framework before the color filter layer is applied. This preliminary action enables the spacer height to exceed conventional limits while keeping the manufacturing process efficient.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention applies different properties to different regions: the black matrix regions are designed with specific thickness for color resistance, while the spacer regions maintain uniform thickness for structural support. This local differentiation allows the color filter layer to be deposited uniformly without being affected by variations in black matrix thickness.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If exposure degree is controlled to adjust spacer height, then manufacturing flexibility increases, but black film thickness becomes uneven leading to increased defect rates

Engineering Contradiction:

Improvespacer height adjustabilityVSAvoidcolor filter defect rate

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The black matrix and spacers are formed in advance as an integral structure, establishing the basic framework before the color filter layer is applied. This preliminary action enables the spacer height to exceed conventional limits while keeping the manufacturing process efficient.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the critical parameter from black film thickness to color filter layer thickness. By making the color filter layer thinner (500-2000 nm) compared to the black matrix (3-5 um), the system achieves the required 3-4 um liquid crystal layer thickness without requiring high light sensitivity materials, thereby reducing defects.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8792077B2Color filter, manufacturing method thereof, and liquid crystal panel with the same

Publication Date: 2014.07.29 TCL CHINA STAR OPTOELECTRONICS TECHNOLOGY CO LTD

AI summary

The present disclosure provides color filter and a manufacturing method thereof, and a liquid crystal panel with the color filter. The color filter includes a substrate, a black matrix formed on the substrate, a number of spacers integrally formed with the black matrix; and a color filter with a thickness thereof being less than that of the black matrix. Color ink is disposed in the black matrix and is hardened to form the color filter layer. The black matrix and the spacers are integrally formed and made of the black film, which simplifies the manufacturing process of the color filter. Additionally, since the color filter layer is formed by the ink jet printing method, the height of the color filter is unlimited, which allows the black matrix and the spacers to be made of conventional material, and improves the yield rate of the color filter.