Color Filter Substrate Laser Transfer Black Matrix Elimination
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Solution Overview
Problem
The fabrication of color filter substrates for liquid crystal display devices is complex and costly due to the need for repeated photolithographic processes, particularly in forming the black matrix layer, which requires coating, exposing, and etching of metal materials with high optical density, leading to high manufacturing costs.
Innovation Solution
A method involving the use of thermal imaging with color filter transcription films, where a light-to-heat conversion layer transforms laser energy into thermal energy to transfer color filter patterns onto a substrate, eliminating the need for a black matrix formed by photolithography, and incorporating dye-absorbing layers to enhance color purity and reproducibility with thinner color filter layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If photolithography processes are used to form the black matrix layer, then the black matrix can be formed with high optical density, but the manufacturing process becomes complex and costly due to repeated coating, exposing, and etching
Solution Approach 1:
The patent extracts and eliminates the black matrix layer from the color filter substrate structure. By forming color filter patterns directly in border regions without requiring a separate black matrix layer, the invention removes the photolithography processes needed to create the black matrix, thereby reducing fabrication complexity while maintaining color purity through direct pattern formation
Solution Approach 2:
The color filter patterns formed in border regions serve multiple functions: they act as both the color filter elements and replace the function of the black matrix layer in preventing light leakage. This multi-functionality eliminates the need for separate black matrix formation processes while achieving the same optical isolation effect
2Object-affected harmful factors
If photolithography processes are used to form the black matrix layer, then the black matrix can be formed with high optical density, but manufacturing costs increase due to repeated coating, exposing, and etching
Solution Approach 1:
The invention extracts and eliminates the black matrix layer and its associated photolithography processes from the manufacturing workflow. By forming color filter patterns directly in border regions, the patent removes multiple coating, exposing, and etching steps, thereby reducing manufacturing costs while achieving the same optical isolation function
Solution Approach 2:
The patent merges the function of the black matrix layer with the color filter patterns in border regions. By combining these functions into a single structural element, the invention eliminates the need for separate black matrix formation processes, reducing both manufacturing complexity and cost
3Manufacturing precision
If thicker color filter layers are used, then color purity may be improved, but the fabrication process becomes more complex and time-consuming
Solution Approach 1:
The patent applies different color filter patterns selectively in border regions versus sub-pixel regions. By forming color filter patterns only where needed (in border regions) and using the existing color filter layers in sub-pixel regions, the invention achieves color purity without requiring uniform thickening of the entire color filter layer, thereby maintaining fabrication efficiency
Solution Approach 2:
The invention applies color filter patterns partially only in border regions rather than uniformly across the entire substrate. This partial action approach achieves the necessary color isolation function in critical areas without the need to process the entire color filter layer, reducing fabrication time and improving productivity
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, reduces costs, and improves color reproducibility by using thinner color filter layers and dye-absorbing layers, while maintaining the functionality of the black matrix, thus enhancing productivity and color accuracy.
Implementation Method 1
a light-to-heat conversion layer transforms laser energy into thermal energy to transfer color filter patterns onto a substrate
Data Source
AI summary
A color filter substrate for a liquid crystal display device includes a substrate having first, second and third sub-pixel regions and first, second and third border regions between adjacent sub-pixel regions, first red, first green and first blue color filter patterns at the first, second and third sub-pixel regions, respectively, and second red, second green and second blue color filter patterns at each of the first, second and third border regions.