Color Filter Ink with Wax Beads for Precision Ejection
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Solution Overview
Problem
Conventional color filter fabrication methods, such as inkjet printing, face challenges with ink nonuniformity and overlapping issues, leading to increased manufacturing costs and reduced processing yield, particularly in forming fine-pitch patterns for wide-screen displays like LCDs.
Innovation Solution
Incorporating wax beads into the color filter ink and using a predetermined voltage between the inkjet head and transparent electrodes to precisely eject and position the ink within pixel areas, ensuring accurate deposition and removal of carriers to prevent bleeding and enhance pattern resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional inkjet printing is used to eject color filter ink, then the fabrication process can be simplified and R/G/B pixels can be simultaneously formed, but ink nonuniformity and overlapping occur leading to color nonuniformity between neighboring pixel rows
Solution Approach 1:
The patent changes the physical state of the ink by incorporating wax beads that melt at a specific temperature. The ink is ejected in a semi-solid state and then melted by heating to achieve uniform distribution. This parameter change (from solid/semi-solid to liquid state) resolves the nonuniformity issue while maintaining the efficiency of simultaneous pixel formation.
Solution Approach 2:
The patent utilizes phase transition of the wax beads from solid to liquid state through controlled heating. The ink is ejected with wax beads in a semi-solid state, then heated to melt the wax and achieve uniform ink distribution across pixels. This phase transition prevents overlapping and nonuniformity while maintaining high productivity.
2Ease of manufacture
If ink is ejected into pixel regions using conventional inkjet printing, then the process is simplified, but ink may overflow on the black matrix and flow into neighboring pixels causing bleeding phenomenon
Solution Approach 1:
The patent changes the viscosity and flow characteristics of the ink by using wax beads that are melted at a controlled temperature after ejection. The ink is deposited in a controllable semi-solid state and then uniformly distributed through heating, preventing overflow and bleeding while maintaining ease of manufacture.
Solution Approach 2:
The patent replaces the conventional mechanical ink ejection and drying system with a thermal field-based system. Instead of relying solely on mechanical ejection precision and air drying, the patent uses controlled heating to melt the wax beads and achieve uniform distribution, thereby preventing bleeding while maintaining process simplicity.
3Manufacturing precision
If multiple scanning operations are performed using different nozzles to reduce color nonuniformity, then ink distribution can be improved, but ink may overlap at several portions of each pixel row increasing manufacturing cost and reducing yield
Solution Approach 1:
The patent uses phase transition of wax beads from solid to liquid through controlled heating to achieve uniform ink distribution in a single scanning operation. The melted wax naturally distributes the ink uniformly across the pixel region without overlapping, thereby maintaining high processing yield while achieving excellent uniformity.
Solution Approach 2:
The patent extracts the ink distribution problem from the mechanical ejection process and solves it through a separate thermal processing step. By separating the ejection and distribution functions, the patent achieves uniform distribution without requiring multiple scanning operations, thus maintaining high 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 method reduces color nonuniformity and manufacturing costs by precisely injecting ink into pixels, improving the formation of fine-pitch patterns and increasing the yield of high-quality color filters for wide-screen displays.
Implementation Method 1
heating and melting the wax beads
Implementation Method 2
heating and evaporating the carriers
Implementation Method 3
applying a predetermined voltage between the inkjet head and the transparent electrodes such that the ejected color filter ink is precisely injected into each of the R/G/B pixels
Data Source
AI summary
A color filter and a fabrication method thereof are provided. In the method, color filter ink that includes wax beads is ejected by an inkjet printing process. A black matrix defining R/G/B pixels is formed on a first surface of a substrate and transparent electrodes are formed on a second surface of the substrate opposite to the first surface at positions corresponding to the R/G/B pixels. The fabricated color filter ink is injected into an inkjet head, and the color filter ink is ejected from the inkjet head into each of the R/G/B pixels. A predetermined voltage is applied between the inkjet head and the transparent electrode such that the ejected color filter ink is precisely injected into each of the R/G/B pixels.