Color Filter Mask Light Regulating Structure for Spacer Flatness
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Solution Overview
Problem
The existing methods for forming color filter layers in liquid crystal displays result in non-uniform base surfaces of columnar spacers due to the fluidity of liquid photoresist and height differences, leading to deformation and reduced image quality, especially as resolution increases and black matrix dimensions narrow.
Innovation Solution
A mask with a light regulating structure, such as a slit or translucent film, is used to control the exposure of the color filter layer, ensuring a flat base for the columnar spacer by varying slit width or transmittance progressively from the sides to the center, improving the flatness and supporting effect of the spacer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid photoresist is used to form color filter layers, then the color filter layer can be formed through curing, but the fluidity of liquid photoresist and height difference between black matrix cause non-uniform base surface of columnar spacer
Solution Approach 1:
The patent applies preliminary action by forming a flattening layer between the color filter layer and the columnar spacer before the columnar spacer is formed. This flattening layer pre-compensates for the non-uniform base surface caused by liquid photoresist fluidity and black matrix height differences, ensuring that when the columnar spacer is subsequently formed, it rests on a uniform surface.
Solution Approach 2:
The flattening layer acts as an intermediary element between the color filter layer and the columnar spacer. It mediates the interface between these two structures, absorbing the surface non-uniformity and providing a flat foundation for the columnar spacer, thereby decoupling the manufacturing processes.
2Measurement precision
If the black matrix is narrowed to achieve higher resolution, then display resolution improves, but the flatness difference of the columnar spacer base increases and deformation becomes more prominent
Solution Approach 1:
The flattening layer is formed in advance before the columnar spacer fabrication, pre-compensating for surface non-uniformity. This preliminary action ensures that even as black matrix dimensions are reduced for higher resolution, the columnar spacer base remains flat and uniform.
3Reliability
If the columnar spacer is positioned on the black matrix at the center position of the gate line region, then deformation is minimized, but the design flexibility of the columnar spacer is limited
Solution Approach 1:
The patent extracts the flattening function from the black matrix/columnar spacer interface and implements it through a separate flattening layer. This separation allows the columnar spacer to be positioned more flexibly without being constrained to the center position of the gate line region, as the flattening layer ensures uniform support regardless of position.
Solution Approach 2:
The flattening layer serves as an intermediary that decouples the positioning constraints. By providing a uniform base surface, it allows the columnar spacer to be positioned at various locations (not just center position) while maintaining reliability and minimizing deformation, thereby increasing design flexibility.
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 enhances the flatness of the columnar spacer base, reduces deformation, and improves the supporting effect, allowing for higher design flexibility and better image quality by ensuring uniformity and precision in the assembly of the color filter substrate.
Implementation Method 1
in an exposure process of the color filter layer, regulating an exposure degree of a portion of the color filter layer corresponding to the base of the columnar spacer by the light regulating structure in the mask for forming color filter layer
Data Source
AI summary
A mask for forming color filter layer, a method for fabricating a color filter substrate and a color filter substrate are provided. A light regulating structure is disposed in a portion of a transparent region of the mask for forming color filter layer, and the light regulating structure is disposed at a position corresponding to a base of a columnar spacer above the color filter layer.