Color Filter Ink Layers With Solvent-Vapor Thickness Equalization
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Solution Overview
Problem
Conventional methods for fabricating color filters using inkjet printing result in non-uniform thickness of ink layers within pixels, leading to light leakage and blurry images due to varying drying conditions and mass flows, which degrade color characteristics.
Innovation Solution
A method involving the formation of a black matrix on a substrate, followed by inkjet printing of liquid ink layers, and subsequent exposure to solvent vapor to mobilize and normalize the surfaces of dried ink layers, ensuring uniform thickness through controlled surface tension and drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional inkjet printing is used to form ink layers in pixels, then the fabrication process is simplified and costs are reduced, but the ink layer thickness becomes non-uniform leading to degraded color characteristics
Solution Approach 1:
A preliminary drying step is performed to form a solid ink layer before the final drying step. This preliminary action creates a stable base structure that prevents non-uniform thickness during subsequent processing, resolving the contradiction between simple fabrication and precise thickness control
Solution Approach 2:
A solvent layer is introduced as an intermediary substance between the ink layer and the environment. This solvent layer mediates the drying process by controlling solvent evaporation rates, thereby achieving uniform ink layer thickness while maintaining the simplicity of the inkjet printing process
2Productivity
If rapid drying is applied to improve productivity, then fabrication time is reduced, but mass flows occur during drying causing non-uniform ink layer thickness
Solution Approach 1:
A preliminary drying step is performed at controlled conditions before final rapid drying. This preliminary action removes excess solvent gradually, preventing mass flows and non-uniform thickness that would occur during rapid drying, thus enabling both high productivity and precision
Solution Approach 2:
The drying process is divided into periodic stages: preliminary drying at controlled rates followed by final rapid drying. This periodic action allows the ink layer to stabilize between drying phases, preventing mass flows while maintaining overall fabrication efficiency
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 results in color filters with uniform ink layer thicknesses, reducing light leakage and image blurring, thereby enhancing color characteristics and process efficiency.
Implementation Method 1
penetrating a solvent vapor into surfaces of the dried liquid ink layers to form ink layers having mobile surfaces
Implementation Method 2
ensuring uniform thickness through controlled surface tension and drying processes
Implementation Method 3
drying the liquid ink layers, penetrating a solvent vapor into surfaces of the dried liquid ink layers
Data Source
AI summary
A method of manufacturing a color filter forming a black matrix on a substrate, the black matrix defining a plurality of pixels, forming liquid ink layers within the pixels and drying the liquid ink layers, penetrating solvent vapor into surfaces of the dried liquid ink layers to form ink layers have mobile surfaces, and drying the ink layers having the mobile surfaces.