Display Panel Light Shielding via Black Matrix and Gate Layer Integration
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Solution Overview
Problem
The complexity of the LTPS process and the multiple mask layers in liquid crystal display manufacturing hinder the improvement of aperture ratio and simplify the display panel manufacturing process.
Innovation Solution
A display panel structure with a black matrix, poly silicon layer, gate layer, and source-drain layer on a first substrate, combined with a second substrate, where the black matrix shields surrounding light and the gate and source-drain layers shield backlight, eliminating the need for additional shield layers and simplifying the manufacturing process by using a color resistant layer for planarization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the LTPS process with multiple photo mask steps is used to improve aperture ratio, then the aperture ratio can be improved, but the manufacturing process complexity increases significantly
Solution Approach 1:
The patent combines the shield layer function with the color filter layer by forming openings in the color filter layer at the same positions where shield layers would traditionally be required. This merging eliminates the need for separate shield layer deposition steps and reduces the number of photo mask processes from 10-12 steps to fewer steps, thereby maintaining high aperture ratio while significantly simplifying the manufacturing process
Solution Approach 2:
The patent extracts the shielding function from the traditional separate shield layer and integrates it into the color filter layer structure. By forming openings in the color filter layer, the shielding capability is achieved without requiring additional shield layer materials or deposition processes, thus reducing process complexity while preserving aperture ratio
2Object-affected harmful factors
If additional shield layers and flat layers are added to ensure light shielding performance, then light shielding performance is improved, but the manufacturing process and material usage become more complex
Solution Approach 1:
The color filter layer is designed to serve multiple functions: it provides color filtering, planarization, and light shielding capabilities. By forming openings in the color filter layer at appropriate positions, the layer simultaneously achieves shielding performance without requiring separate shield layers or flat layers, thus reducing both material usage and process complexity while maintaining effective light shielding
Solution Approach 2:
The patent merges the shielding function with the color filter layer structure, eliminating the need for separate shield layers and flat layers. This consolidation reduces the number of manufacturing steps and material layers while achieving the same or better light shielding performance through the integrated design
3Reliability
If multiple mask layers are used in the LTPS process to ensure TFT performance, then TFT performance is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the shield layer formation with the color filter layer fabrication process by forming openings in the color filter layer. This integration reduces the number of photo mask steps from 10-12 to fewer steps, thereby maintaining TFT performance requirements while significantly improving manufacturing efficiency and reducing production time
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 solution simplifies the display panel manufacturing process, reduces material usage, and enhances the aperture ratio by eliminating the shield layer and flat layer processes, while maintaining performance.
Implementation Method 1
the black matrix shelters the surrounding light which is incident from the first substrate onto the poly crystal layer
Implementation Method 2
the gate layer and the source-drain layer shelter the backlight which is incident from the second substrate onto the poly crystal layer
Data Source
AI summary
A display panel and the method of manufacturing the same, includes a first substrate disposed relatively to a second substrate, disposed above the first substrate. A black matrix, a poly silicon layer, a gate layer and a source drain layer disposed successively on the first substrate along direction facing the second substrate. The black matrix shelters the surrounding light which is incident from the first substrate onto the poly crystal layer, and the gate layer and the source-drain layer shelter the backlight which is incident from the second substrate onto the poly crystal layer. The manufacturing method of the display panel of the present invention could be simplified by the method described above.