Color Filter Substrate Concave Pixel Structure
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Solution Overview
Problem
The existing methods for manufacturing color filter substrates require repetitive processes for forming colored layers, leading to increased costs due to the need for additional steps in forming white-pigment-containing resin layers, which complicates the formation of colored and non-colored pixels.
Innovation Solution
A color filter substrate design that incorporates first and second colored pixels within concave portions of the substrate, with a non-colored pixel positioned at a thicker area where no colored layer is formed, eliminating the need for additional resin layers and allowing for efficient pixel formation and stable cell gap maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional processes for forming colorless resin layers or white-pigment-containing resin layers are performed to create non-colored pixels, then non-colored pixels can be formed, but manufacturing cost increases due to additional process steps
Solution Approach 1:
The invention extracts the non-colored pixel formation from the conventional resin layer deposition process. Instead of adding colorless or white-pigment-containing resin layers, the patent utilizes the substrate itself as the non-colored pixel structure by selectively removing resin layers in specific regions, thereby eliminating the need for additional resin deposition processes for white pixels
Solution Approach 2:
The invention inverts the conventional approach by instead of adding material (colorless resin or white pigment) to create non-colored pixels, it removes material (colored resin layers) to expose the substrate, which naturally provides the non-colored pixel function without requiring additional resin layers
2Adaptability or versatility
If additional processes for forming colorless resin layers or white-pigment-containing resin layers are performed to create non-colored pixels, then non-colored pixels can be formed, but manufacturing complexity increases due to additional patterning steps
Solution Approach 1:
The invention merges the non-colored pixel formation with the existing colored pixel formation processes. By using the same etching mask and etching steps that define colored pixel regions, the non-colored pixels are simultaneously formed without requiring separate deposition and patterning processes, thereby reducing overall process complexity
Solution Approach 2:
The substrate serves multiple functions: it acts as both the structural base and the non-colored pixel element. The same substrate that provides mechanical support also functions as the white pixel structure when colored resin layers are removed, eliminating the need for separate white pixel formation processes
3Manufacturing precision
If conventional methods are used to form non-colored pixels with resin layers, then pixels can be formed uniformly, but cell gap stability decreases due to protrusion from colored layers
Solution Approach 1:
The invention applies different local qualities to different pixel regions. Colored pixels have resin layers of specific thicknesses, while non-colored pixels have the substrate exposed with its original thickness. This local differentiation ensures that non-colored pixels do not protrude, maintaining uniform cell gap while preserving pixel formation precision through selective etching
Data Source
AI summary
In an electro-optical device 100, a color filter substrate 20 is provided with colored pixels, which are: a red pixel 2(R) with a colored layer 28(R) formed inside a concave portion 25(R) formed in a first surface 20s of a light-transmissive substrate 20d, a green pixel 2(G) with a colored layer 28(G) formed inside a concave portion 25(G) formed in said surface, and a blue pixel 2(B) with a colored layer 28(B) formed inside a concave portion 25(B) formed in said surface. In addition, in the substrate 20d, a non-colored pixel 2(W), at which no colored layer is provided, is provided outside the concave portion 25(R), 25(G), 25(B) at a position where the thickness of the substrate 20d is greater than that at the colored pixels.