Color Filter Manufacturing via Substrate-Side Light Reflection
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Solution Overview
Problem
Prior methods for manufacturing color filters in liquid crystal displays result in non-uniform edge luminance and color, and poor contrast due to gaps between the black matrix and color layers during the back exposing process.
Innovation Solution
A method involving the use of a reflection sheet capable of reflecting light, disposed on one side of the transparent substrate with the black matrix, to improve exposing efficiency by reflecting incident light back onto the substrate, ensuring complete exposure between the black matrix and color layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If back exposing technic is employed in the fabrication of the color layers, then the contraposition of the black matrix and the color layers is achieved, but there is a gap between the black matrix and the color layers due to insufficient exposing
Solution Approach 1:
The patent inverts the traditional exposing approach by placing the light source on the opposite side of where the pattern is formed. Instead of exposing from the color layer side, light is introduced from the substrate side, allowing light to pass through the transparent substrate and black matrix to expose the photosensitive material on the color layer side. This inversion ensures complete exposing without gaps while maintaining precise pattern formation.
Solution Approach 2:
The patent changes the dimension of light propagation by transitioning from surface-level exposing to through-substrate exposing. Light travels through the thickness of the substrate and black matrix layers, exposing the photosensitive material from the opposite direction. This dimensional change enables complete exposing throughout the entire structure, eliminating the gap problem at the edges.
2Ease of manufacture
If back exposing technic is employed, then the color layers can be formed, but the contrast of the liquid crystal display module deteriorates due to gaps between black matrix and color layers
Solution Approach 1:
By inverting the exposing direction to illuminate from the substrate side rather than the color layer side, the patent achieves complete exposing of the photosensitive material. This ensures full development of color layers with proper adhesion to the black matrix, eliminating gaps that would otherwise reduce display contrast while maintaining ease of manufacturing.
3Device complexity
If traditional exposing method is used, then the process is simple, but non-uniform edge luminance and color occur
Solution Approach 1:
The patent maintains relatively simple process equipment while changing the dimension of light propagation through the substrate. Light is introduced from the substrate side and travels through the thickness of the structure to expose the photosensitive material on the opposite side. This dimensional change in light path ensures uniform exposing across the entire area, including edges, without significantly complicating the exposing process.
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 eliminates gaps between the black matrix and color layers, resulting in uniform edge luminance and improved contrast in liquid crystal display modules.
Implementation Method 1
disposing a reflection sheet capable of reflecting light on a first side of the transparent substrate to be exposed
Data Source
AI summary
A method for manufacturing color filter, a color filter, and a display device including the color filter are disclosed. The method for manufacturing a color filter includes: forming a black matrix on a transparent substrate; forming a photosensitive resist layer on the transparent substrate with the black matrix; disposing a reflection sheet capable of reflecting light on a first side of the transparent substrate to be exposed, the first side being provided with the black matrix; disposing a mask on a second side of the transparent substrate to be exposed, the second side being not provided with the black matrix; and carrying out an exposing process from the second side of the transparent substrate.