Integrated Protective and Black Matrix Layers in Display Devices
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Solution Overview
Problem
The manufacturing process of display devices, particularly LCDs, is complex due to the need for precise alignment and multiple layers, which increases the risk of misalignment and light leakage, complicating the integration of components like the color filter and light blocking members.
Innovation Solution
A display device design that includes a base substrate with distinct light blocking and transmitting areas, where a gate line and data line are disposed on the blocking areas, and a thin film transistor connected by a pixel electrode through a contact hole in the protective and black matrix layers, with a light blocking pattern overlapping the transistor area to prevent light leakage, and a method for manufacturing this device that simplifies the formation of these layers using a mask with light transmitting and blocking portions to develop the black matrix material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a color filter and light blocking member are disposed on the display substrate (BOA structure), then misalignment between substrates is prevented, but the manufacturing process becomes complex with multiple layers
Solution Approach 1:
The patent combines the protective layer and black matrix layer into a single integrated layer structure. The black matrix is formed as part of the protective layer deposition process, eliminating the need for separate black matrix deposition and alignment steps. This merging reduces manufacturing complexity while maintaining the alignment precision benefits of the BOA structure.
Solution Approach 2:
The protective layer serves multiple functions: it provides electrical insulation, mechanical protection, and forms the black matrix for light blocking. By making the protective layer multi-functional, the patent eliminates the need for a separate dedicated black matrix layer, simplifying the manufacturing process while maintaining alignment precision.
2Manufacturing precision
If multiple layers (protective layer, black matrix, color filter) are formed sequentially, then precise alignment is required, but the risk of misalignment and light leakage increases
Solution Approach 1:
The protective layer and black matrix are formed simultaneously in a single deposition process rather than sequentially. This eliminates alignment interfaces between separate layers, removing the risk of misalignment and light leakage that would occur at the boundaries between independently formed layers.
Solution Approach 2:
The black matrix pattern is defined using the same mask that defines the protective layer pattern. By performing the patterning action preliminarily and simultaneously for both layers, the patent ensures perfect alignment without requiring subsequent alignment steps that could introduce misalignment errors.
3Adaptability or versatility
If separate processes are used for protective layer and black matrix formation, then process flexibility is maintained, but manufacturing efficiency decreases
Solution Approach 1:
The protective layer and black matrix are deposited in a single process step using a multi-functional deposition system. This merging of processes doubles the manufacturing efficiency by eliminating one complete process cycle, while the process remains flexible through programmable deposition parameters and mask design.
Solution Approach 2:
The deposition process is designed to perform multiple functions (forming both protective layer and black matrix) simultaneously. This universal process approach maintains flexibility through parameter control while achieving high productivity by eliminating sequential processing steps.
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 design simplifies the manufacturing process by allowing for the simultaneous formation of protective and black matrix layers, reducing the risk of misalignment and light leakage, thereby enhancing the efficiency and accuracy of the display device production.
Implementation Method 1
disposing a mask comprising a light transmitting portion, a semi-light transmitting material, exposing the black matrix forming material using a mask including a light transmitting portion, a semi-light transmitting portion and a light blocking portion, and developing the black matrix forming material
Data Source
AI summary
A display device includes: a base substrate comprising a first light blocking area extending in a first direction, a second light blocking area extending in a second direction intersecting the first direction and a light transmitting area defined by the first light blocking area and the second light blocking area; a gate line on the base substrate at the first light blocking area; a data line on the base substrate at the second light blocking area; a thin film transistor connected to the gate line and the data line; a protective layer on the thin film transistor; a black matrix on the protective layer at at least one of the first light blocking area and the second light blocking area; and a pixel electrode connected to the thin film transistor through a contact hole defined in the protective layer and the black matrix.