Color Filter Light Exposure Process Uniformity
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Solution Overview
Problem
Conventional methods for fabricating color filters, such as inkjet printing, face challenges in achieving uniform color distribution and productivity due to quick hardening of coloring agents and difficulty in controlling ink ejection, leading to suboptimal transmittance and color reproduction.
Innovation Solution
A color filter design featuring light-sensitive cyan, magenta, and yellow developing layers with a patterned matrix layer and protective layer, formed on a substrate like glass or polymer resin, allowing for simultaneous formation of multiple colors through a light exposure process, ensuring uniformity and high productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing is used to fabricate color filters, then multiple colors can be formed through one printing process, but the coloring agent formulation degrades or thickens before being dispersed onto the substrate
Solution Approach 1:
The patent applies preliminary action by preparing the coloring agent formulation in advance and storing it in a reservoir, then dispensing it through a dispensing head at the moment of printing. This separates the preparation phase from the execution phase, allowing the formulation to be pre-mixed without degradation while ensuring fresh material is applied to the substrate at the time of printing.
Solution Approach 2:
The patent introduces a dispensing head as an intermediary component between the coloring agent reservoir and the substrate. This intermediary device controls the precise dispensing of the coloring agent formulation, preventing premature thickening or degradation while ensuring accurate material delivery to the substrate surface at the optimal time.
2Productivity
If inkjet printing is used to fabricate color filters, then multiple colors can be formed through one printing process, but it is difficult to control the amount of ink ejected through inkjet nozzles and crosstalk between the nozzles occurs
Solution Approach 1:
The patent segments the coloring agent delivery system into separate dispensing heads for different colors, with each dispensing head independently controlling its own material ejection. This segmentation prevents crosstalk between adjacent nozzles by physically separating their operation, while maintaining high productivity through parallel processing of multiple colors in a single printing pass.
Solution Approach 2:
The patent incorporates feedback mechanisms to monitor and control the amount of coloring agent ejected from each dispensing head. By monitoring ejection parameters and adjusting the dispensing process in real-time, the system maintains precise control over material quantity while preventing over- or under-dispensing that could lead to crosstalk or poor color formation.
3Manufacturing precision
If conventional methods such as dyeing or pigment dispersion are used, then color filters can be fabricated, but the processes are time-consuming and less efficient
Solution Approach 1:
The patent replaces conventional mechanical dyeing and pigment dispersion methods with a direct dispensing system that deposits coloring agent formulation precisely where needed. This substitution of the fabrication mechanism enables faster processing by eliminating the need for lengthy soaking, rinsing, and drying cycles associated with traditional methods, while maintaining high manufacturing precision through controlled dispensing.
Solution Approach 2:
The patent changes the key parameters of the fabrication process by using a controlled dispensing approach rather than bulk dyeing. By adjusting parameters such as dispensing rate, material concentration, and application timing, the system achieves both high productivity and high manufacturing precision, forming color filters faster while maintaining superior color quality and uniformity.
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 ensures uniform transmittance, color reproduction, and thickness of pixels, enabling high-productivity color filter production and excellent color expression in display devices.
Implementation Method 1
light-sensitive color developing layers which are exposed to light to be developed into pixel portions having respective colors
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A
AI summary
Provided is a color filter that can ensure high productivity by producing all colors in a single process irrespective of colors of pixels and can improve uniformity in the transmittance, color reproduction, and thickness of pixels having their colors. The color filter includes: a substrate; and at least one of light sensitive color developing layers stacked on the substrate, the light sensitive color developing layers having pixel portions, wherein the pixel portions are defined by partial color developing regions formed by exposure and development of the light sensitive color developing layer.