Display Panel Mask Reduction via Height-Differentiated Patterns
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Solution Overview
Problem
The existing manufacturing processes for display panels require multiple masks, which complicates the production and increases costs, and there is a need to simplify the process while maintaining the efficiency of reflective and polarizing components.
Innovation Solution
The proposed solution involves forming a display panel with a base substrate that includes a reflective pattern and grid patterns with different heights, allowing for the use of fewer masks during manufacturing by using a single mask to create both the reflective part and the polarizing part, and applying this approach to the mother substrate as well, thereby reducing the overall number of masks required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used to form reflective patterns and grid patterns separately, then the manufacturing precision and functional separation are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the formation of reflective patterns and grid patterns into a single mask step. The mask is designed with both reflective pattern regions and grid pattern regions, allowing both functional elements to be created simultaneously in one photolithography process, thereby reducing the number of masks from multiple to one while maintaining manufacturing precision
Solution Approach 2:
The single mask serves multiple functions by incorporating both reflective pattern definitions and grid pattern definitions. This multi-functional mask design allows it to perform the roles of what would traditionally require separate masks for reflective areas and grid areas, simplifying the overall manufacturing process
2Manufacturing precision
If multiple masks are used for forming different patterns, then the functional separation of reflective and polarizing components is improved, but the productivity decreases due to multiple processing steps
Solution Approach 1:
The patent merges the manufacturing steps for reflective patterns and grid patterns into a single photolithography process using one mask. This consolidation reduces the number of sequential processing steps, thereby increasing manufacturing throughput and productivity while still achieving accurate functional separation through the mask design
3Ease of manufacture
If a single mask is used to form both reflective and polarizing parts, then the ease of manufacture is improved, but the manufacturing precision may be compromised
Solution Approach 1:
The mask is designed with distinct regions: a reflective pattern region that defines where reflective material should be deposited, and a grid pattern region that defines where grid structures should form. This regional differentiation within a single mask maintains manufacturing precision while simplifying the overall process by eliminating the need for multiple masks
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 simplifies the manufacturing process, reduces costs, and maintains the efficiency of the reflective and polarizing components, enabling the production of display panels with improved light-use efficiency and reduced power consumption.
Implementation Method 1
a grid of metallic wires separated from each other selectively transmits or reflects polarizations of electronic waves. That is, when an arrangement distance of the metallic wires is shorter than that of a wavelength of an incident electronic wave, a polarization component parallel to the metallic wires is reflected, and a polarization component perpendicular to the metallic wires is transmitted
Implementation Method 2
a reflective pattern overlapping the non-display area
Data Source
AI summary
A display panel including a base substrate which includes a display area and a non-display area, a polarizing member disposed on a surface of the base substrate and including a plurality of grid patterns overlapping the display area and a reflective pattern overlapping the non-display area, and a pixel array layer which overlaps the polarizing member and is insulated from the polarizing member. A first height from the surface of the base substrate to an upper surface of the reflective pattern is different from a second height from the surface of the base substrate to upper surfaces of the grid patterns.