Color Filter Substrate Integrated Photolithography

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Solution Overview

Problem

The existing manufacturing processes for color filter substrates in display panels are inefficient, as they require separate processes for color filter units, black matrix units, and spacer elements, leading to complexity and potential inconsistencies in display uniformity.

Innovation Solution

The proposed method integrates the manufacturing of photoresists and spacer elements with color filter units using a photolithographic process, where photoresists are made from the same material and during the same process as the color filter units, and spacer elements are made from polyimide materials, allowing for improved alignment and uniformity across multiple manufacturing stages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate manufacturing processes are used for color filter units, black matrix units, and spacer elements, then each component can be independently controlled, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improveindependent component controlVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the manufacturing of color filter units, black matrix units, and spacer elements into a single integrated photolithographic process. Photoresist material is applied to form all three component types simultaneously through one exposure and development cycle, eliminating the need for separate manufacturing steps while maintaining independent control over each component's formation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The photolithographic process is designed to perform multiple functions simultaneously: it patterns color filter units in transparent regions, creates black matrix units in opaque regions, and forms spacer elements at specific locations, all within a single manufacturing operation that serves multiple purposes

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate manufacturing processes are used for color filter units, black matrix units, and spacer elements, then each component can be independently controlled, but production time increases

Engineering Contradiction:

Improveindependent component controlVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The manufacturing process maintains continuous useful action by forming all component types (color filter units, black matrix units, and spacer elements) in an uninterrupted single photolithographic sequence without intermediate steps or process interruptions, maximizing production efficiency while ensuring each component is properly formed

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Multiple component manufacturing operations are merged into one simultaneous process step, reducing the total production time from multiple sequential operations to a single integrated operation that produces all components in parallel

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If photoresists are made from different materials or processes than color filter units, then material selection is flexible, but alignment consistency and display uniformity deteriorate

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidalignment consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent uses the same photoresist material for forming both the color filter units and the spacer elements, ensuring homogeneous material properties throughout. This uniformity in material composition guarantees consistent alignment and uniform display performance across the entire substrate, as all components are formed from identical photoresist with the same characteristics

Inventive Principle:

Principle #33Homogeneity

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 simplifies the manufacturing process, enhances display uniformity, and improves the efficiency of producing color filter substrates by integrating material and process steps, resulting in a more consistent and efficient production method.

Implementation Method 1

a first photolithographic process is performed to form a first photoresist pattern and a first color filter unit

Methodology Applied

Scientific EffectPhotolithography: Photopolymerisation

Implementation Method 2

a second photolithographic process is performed to form a second photoresist pattern and a plurality of spacer elements

Methodology Applied

Scientific EffectThermal curing: Heat Treatment

Data Source

PatentUS10067273B2Color filter substrate and manufacturing method thereof

Publication Date: 2018.09.04 HON HAI PRECISION INDUSTRY CO LTD

AI summary

A color filter substrate includes a base layer and a number of color filter modules arranged on the base layer. Each color filter module includes two black matrix units arranged on the base layer and separated from each other, three color filter units arranged on the base layer and separated from each other by the two black matrix units, a first spacer element arranged on a first black matrix unit, and a second spacer element arranged on a second black matrix unit. Each color filter module is arranged in a linear arrangement. At least one portion of the first spacer element is made of a same material and during a same manufacturing process as a corresponding at least one of the color filter units. Each color filter unit corresponds to one predetermined color.