Flat Panel Display Spacer Formation via Pigment Width Control
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Solution Overview
Problem
Existing manufacturing methods for liquid crystal display devices require separate processes for forming spacers, which increases complexity and cost, and struggle to maintain even cell gaps effectively.
Innovation Solution
A method where spacers are formed simultaneously with color filters by varying the widths of pigment layers on a substrate, allowing for controlled spacer heights without additional processing steps, simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate manufacturing processes are used for spacers, then spacer formation is achieved, but process complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the spacer formation process with the color filter formation process by depositing pigment layers that serve dual functions: as color filters in pixel areas and as spacers in black matrix areas. This integration eliminates separate spacer manufacturing steps while maintaining reliable cell gap control.
Solution Approach 2:
The pigment layers deposited during color filter formation are designed to serve multiple functions: they act as color filters in pixel regions and simultaneously function as spacers in black matrix regions. This multi-functionality reduces process complexity while ensuring proper cell gap maintenance.
2Reliability
If separate manufacturing processes are used for spacers, then spacer formation is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines spacer and color filter formation into a single manufacturing sequence, eliminating the need for separate spacer deposition and patterning steps. This merging of processes directly reduces manufacturing cost while maintaining reliable cell gap control.
Solution Approach 2:
By designing pigment layers that serve both as color filters and spacers, the patent eliminates the need for separate spacer materials and processes, thereby reducing material costs and process costs while ensuring reliable cell gap maintenance.
3Ease of manufacture
If uniform pigment layer widths are used, then manufacturing is simplified, but spacer height variation cannot be controlled
Solution Approach 1:
The patent applies different pigment layer widths in different regions: uniform widths in pixel areas for color filter consistency, and varied widths in black matrix areas for spacer height control. This local differentiation enables precise spacer height control without complicating the overall manufacturing process.
Solution Approach 2:
The patent controls spacer height by varying the width parameter of pigment layers in black matrix areas. By changing this geometric parameter locally, the invention achieves precise control over spacer heights while maintaining manufacturing simplicity through the same deposition process.
4Manufacturing precision
If multiple pigment layer widths are used for spacers, then various spacer heights are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent implements local quality by using varied pigment layer widths only in black matrix areas where spacer height control is needed, while maintaining uniform widths in pixel areas. This localized approach achieves precise spacer height control without significantly increasing overall patterning complexity.
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 simplifies the manufacturing process, reduces costs, and enables the formation of spacers with various heights, effectively maintaining even cell gaps in liquid crystal display devices.
Implementation Method 1
forming a first color filter in a first area among the pixel areas, and a first pigment layer having a first width on a spacer area in the black matrixes, by depositing and patterning a first pigment on the substrate
Data Source
AI summary
Disclosed is a manufacturing method for a spacer in a flat panel display device. The method comprises forming a color filter substrate including: defining pixel areas on a transparent substrate; forming black matrixes surrounding the pixel areas; forming a first color filter in a first area, and a first pigment layer having a first width on a spacer area in the black matrixes by depositing and patterning a first pigment on the substrate; forming a second color filter in a second area, and a second pigment layer having a second width on the spacer area in the black matrixes by depositing and patterning a second pigment on the substrate; and forming a third color filter in a third area, and a third pigment layer having a third width on the spacer area in the black matrixes by depositing and patterning a third pigment on the substrate.