Color Filter Manufacturing Using Segmented Single and Multi-Film Regions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional color filter manufacturing processes for liquid crystal on silicon (LCoS) panels are time-consuming and costly due to the need for multiple processes to form different colors of photoresists, which complicates the formation of color filters and increases production time and expenses.
Innovation Solution
A method for manufacturing a color filter using a substrate with distinct regions of single-film and multi-film filter units, where a white beam is projected to reflect specific colors, simplifying the process through the use of half-tone masks and reducing the number of required processes from five to three, utilizing color resists to achieve color mixing principles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional color filter process is used to form different colors of photoresists on liquid crystal panel, then color display quality is achieved, but manufacturing cost and process time increase significantly
Solution Approach 1:
The substrate is divided into a first region and a second region, where the first region contains single-film filter units and the second region contains multi-film filter units. This segmentation allows different color filtering mechanisms to coexist on the same panel, enabling both yellow/cyan colors (from single-film) and red/blue/green colors (from multi-film) to be displayed simultaneously through spatial mixing.
Solution Approach 2:
The color filter manufacturing process is made multi-functional by using a unified substrate structure that can accommodate both single-film and multi-film filter units. This universal approach allows the same manufacturing process to produce diverse color filters (yellow, cyan, red, blue, green) without requiring separate production lines or additional processing steps for different color types.
2Manufacturing precision
If conventional color filter process is used to form different colors of photoresists on liquid crystal panel, then color display quality is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the manufacturing of single-film and multi-film color filters into a single integrated process. Both types of filter units are formed on the same substrate using the same manufacturing steps, eliminating the need for separate production processes. This consolidation significantly reduces manufacturing complexity and cost while maintaining the ability to produce high-quality color displays.
3Adaptability or versatility
If five corresponding processes are performed to form pixels of five different colors on liquid crystal panel, then complete color display is achieved, but process complexity and time consumption increase
Solution Approach 1:
The substrate is divided into a first region and a second region, where the first region contains single-film filter units and the second region contains multi-film filter units. This segmentation allows different color filtering mechanisms to coexist on the same panel, enabling both yellow/cyan colors (from single-film) and red/blue/green colors (from multi-film) to be displayed simultaneously through spatial mixing.
4Adaptability or versatility
If five corresponding processes are performed to form pixels of five different colors on liquid crystal panel, then complete color display is achieved, but production efficiency decreases
Solution Approach 1:
The patent merges the manufacturing of single-film and multi-film color filters into a single integrated process. Both types of filter units are formed on the same substrate using the same manufacturing steps, eliminating the need for separate production processes. This consolidation significantly reduces manufacturing complexity and cost while maintaining the ability to produce high-quality color displays.
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 significantly reduces manufacturing costs and shortens the process time while maintaining good optical quality by simplifying the formation of color pixels and achieving efficient color mixing with fewer steps, enabling the production of a cost-effective color filter with improved efficiency.
Implementation Method 1
When a white beam is projected on the color filter, the first region and the second region reflect a plurality of color beams
Data Source
AI summary
A method for manufacturing a color filter is provided. The method includes following steps. A substrate is provided. A first filter layer is formed on a first part of a first region and a first part of a second region of the substrate. A second filter layer is formed on a second part of the second region. A third filter layer is formed on a second part of the first region and a third part of the second region. When a white beam is projected on the color filter, the first region and the second region reflect a plurality of color beams. A color filter manufactured through the method is also provided.