Display Sub-Pixel Area Matching for High-Resolution Light-Shielding Film Alignment
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Solution Overview
Problem
High-resolution display devices face challenges in forming light-shielding films with small pattern intervals, leading to shape inaccuracies and reduced luminance due to photolithography issues, especially when multiple steps are involved.
Innovation Solution
A display device design with sub-pixels having distinct transmission and light-emitting regions, where the difference in area between these regions is minimized, allowing for precise alignment and bonding of substrates to maintain luminance even with shifts during photomask alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photolithography is used to form a light-shielding film with small pattern intervals for high resolution, then the resolution is improved, but the light-shielding film cannot be formed with the desired shape due to light diffraction and scattering
Solution Approach 1:
The light-shielding film formation process is divided into multiple separate steps, where each step forms a portion of the final light-shielding film pattern. This segmentation allows each photolithography step to work with larger, more controllable pattern intervals, avoiding the light diffraction and scattering issues that occur when attempting to form complete fine-pitch patterns in a single step.
Solution Approach 2:
The invention performs preliminary actions by forming intermediate light-shielding film patterns in separate preparatory steps before final assembly. These preliminary patterns are formed with relaxed dimensional constraints, and then combined to create the final high-resolution light-shielding film structure, effectively preparing the system in advance to avoid later alignment and formation difficulties.
2Manufacturing precision
If the light-shielding film is formed in multiple separate steps to achieve small pattern intervals, then the manufacturing precision is improved, but the luminance is reduced due to photomask position shifts
Solution Approach 1:
The invention introduces an intermediary substrate structure that includes reference marks and alignment features. This intermediary structure serves as a mediator between multiple photolithography steps, enabling precise registration and alignment of sequentially formed light-shielding film portions. The reference marks act as intermediaries that transfer positional information across different processing steps, maintaining luminance by ensuring accurate pattern alignment despite multiple fabrication steps.
3Measurement precision
If the interval between patterns is reduced for high resolution, then the resolution is improved, but light diffraction and scattering occur preventing the desired film shape
Solution Approach 1:
The invention transitions from attempting to form complete fine-pitch light-shielding film patterns in a single two-dimensional photolithography step to a multi-step process that effectively adds a temporal dimension. By forming portions of the light-shielding film in separate sequential steps, each with larger effective pattern intervals, the process circumvents the light diffraction and scattering limitations that constrain single-step formation of high-density patterns.
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 ensures that the luminance is preserved and the light-shielding film is formed accurately, preventing the reduction in luminance that occurs with traditional methods, even when shifts occur during the photomask alignment process.
Implementation Method 1
the color filters including transmission regions selectively transmitting lights of specific colors for the respective sub-pixels
Implementation Method 2
the light-shielding film blocking light
Data Source
AI summary
A display device includes a first substrate provided with a display region including a plurality of pixels arranged in a matrix, each of the plurality of pixels having a plurality of sub-pixels, and a second substrate provided with color filters and a light-shielding film, the color filters including transmission regions selectively transmitting lights of specific colors for the respective sub-pixels, the light-shielding film blocking light. The plurality of sub-pixels include a first sub-pixel provided with the transmission region that transmits light of a first color, and a second sub-pixel provided with the transmission region that transmits light of a second color having a luminosity factor lower than that of the light of the first color. A difference in area between a light-emitting region and the transmission region in the second sub-pixel is smaller than a difference in area between a light-emitting region and the transmission region in the first sub-pixel.