Gate Insulating Layer Width Control in Display Device Manufacturing
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Solution Overview
Problem
The manufacturing process of flat panel display devices, such as LCDs, is costly and involves a complex sequence of processes, particularly due to the formation of multiple insulating layers and electrodes, which increases production expenses and complexity.
Innovation Solution
A display device design that includes a first substrate with a gate line, gate electrode, and semiconductor layer, where the gate insulating layer is wider than the gate electrode, and a method of manufacturing involving fewer processes by using the gate insulating layer as a mask for etching the gate electrode, reducing the number of steps and materials needed, and incorporating a second substrate with a liquid crystal layer for polarization control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulating layers and electrodes are formed on the thin film transistor display substrate, then the display device functionality is improved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines multiple insulating layers (gate insulating layer, first passivation layer, second passivation layer) into a single integrated insulating structure that serves multiple functions: electrical insulation, etching mask, and protective layer. This merging reduces the number of separate manufacturing processes while maintaining the required display device functionality.
Solution Approach 2:
The gate insulating layer is designed to serve multiple purposes: it provides electrical insulation between the gate electrode and semiconductor layer, acts as an etching mask during manufacturing, and functions as a protective layer. This multi-functionality reduces the need for separate dedicated layers, simplifying the overall manufacturing process.
2Reliability
If multiple insulating layers and electrodes are formed on the thin film transistor display substrate, then the display device functionality is improved, but the manufacturing cost increases
Solution Approach 1:
By merging multiple insulating layers into a single integrated structure, the patent reduces the number of deposition and patterning processes required, directly lowering manufacturing costs while maintaining the electrical insulation and protective functions needed for display device operation.
Solution Approach 2:
The gate insulating layer serves as its own etching mask during manufacturing, eliminating the need for separate mask layers and reducing material costs. The layer's own structural properties are utilized to perform the masking function, simplifying the manufacturing process and reducing expenses.
3Ease of manufacture
If the gate insulating layer has the same shape as the gate electrode, then the manufacturing process is simplified, but the electrical insulation and process mask functionality is reduced
Solution Approach 1:
The patent introduces asymmetry between the gate insulating layer and gate electrode shapes, with the insulating layer extending beyond the electrode boundaries. This asymmetric design provides additional functional benefits: enhanced electrical insulation at the edges and improved etching mask coverage, while the core region maintains the necessary electrical connection properties.
Solution Approach 2:
The gate insulating layer is formed to extend beyond the gate electrode boundaries in advance, creating a preliminary protective and insulating structure that facilitates subsequent manufacturing steps. This preliminary extension ensures adequate mask coverage and electrical insulation are already in place before other layers are deposited.
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 reduces manufacturing costs and simplifies the production process by minimizing the number of processes required, while maintaining effective display functionality through controlled liquid crystal orientation and polarization.
Implementation Method 1
the polarization of incident light may be controlled to display an image
Implementation Method 2
the orientation of liquid crystal molecules of the liquid crystal layer may be determined
Data Source
AI summary
A display device includes a first substrate including a display area and a non-display area. A gate line and a gate electrode are in the display area. A data line is connected to the gate line. A gate insulating layer is on the gate line and the gate electrode. A semiconductor layer is on the gate insulating layer. A drain electrode and a source electrode are on the semiconductor layer. A first passivation layer is on the drain electrode and the source electrode. A color filter is on the first passivation layer. A common electrode is on the first passivation layer. A second passivation layer is on the common electrode. A pixel electrode is on the second passivation layer. The gate insulating layer has substantially a same shape as a shape of the gate electrode. The gate insulating layer has a width wider than a width of the gate electrode.