Interference Filter LCD Panel Reduces Mask Count
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Solution Overview
Problem
The conventional process for producing Liquid Crystal Display (LCD) panels is time-consuming and costly due to repeated steps and the need for multiple masks in forming red, green, and blue color filters, limiting production efficiency.
Innovation Solution
Incorporating an interference filter into the lower substrate of the LCD panel, which includes a first metal layer, dielectric layer, second metal layer, and organic layer, to replace the conventional color filters, and integrating this process into the production of the array substrate, thereby simplifying the manufacturing steps and reducing the number of masks required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional color filter formation process is used with multiple masks for R, G, and B filters, then color display function is achieved, but production time increases and manufacturing cost increases
Solution Approach 1:
The patent merges the formation of multiple color filters (R, G, B) into a single interference filter structure. Instead of using three separate masks to form R, G, and B color filters sequentially, the invention uses one mask to form an interference filter that provides all three color functions through optical interference effects, thereby reducing the number of manufacturing steps and masks required
Solution Approach 2:
The patent changes the fundamental parameter of color filter formation from absorptive color filters (using dyes or pigments) to interference-based color selection. By controlling the thickness and refractive index of dielectric layers in the interference filter, different colors are achieved through optical interference rather than absorption, enabling a more efficient manufacturing process
2Ease of manufacture
If multiple masks are used to form R, G, and B color filters separately, then color precision is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines three separate color filter formation processes into a single interference filter structure. One mask is used to define the region where the interference filter will be formed, and the subsequent deposition of dielectric layers with controlled thicknesses creates the color-selective properties without requiring separate masks for each color, thereby reducing mask quantity and cost
3Productivity
If conventional five-step process for CF substrate is used, then color display function is achieved, but production time increases
Solution Approach 1:
The patent merges multiple sequential steps (forming R filters, G filters, B filters, Black Matrixes, and transparent conductive layer) into a streamlined process. The interference filter is formed in fewer steps by using one mask instead of three, and the same process sequence is applied to both the array substrate and CF substrate, reducing the overall production cycle time
Solution Approach 2:
The patent creates a universal process that can be applied to both the array substrate and CF substrate. The same interference filter formation methodology is used for both substrates, allowing for standardized, efficient manufacturing that reduces production time across the entire LCD panel fabrication process
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 achieves a color display effect while significantly simplifying the production process, reducing costs, and enhancing the efficiency of LCD panel production by eliminating the need for multiple color filter production steps.
Implementation Method 1
the interference filter includes a first metal layer, a dielectric layer, a second metal layer and an organic layer which are deposited in sequence on the lower substrate
Data Source
AI summary
Embodiments of the present invention provide a Liquid Crystal Display (LCD) panel, including an upper substrate and a lower substrate between which a liquid crystal layer is sealed. The lower substrate includes a plurality of sub-pixel regions arranged in regular patterns. The upper substrate includes Black Matrixes (BM) and an upper transparent conductive layer which are formed in sequence on the bottom surface of an upper transparent substrate. The lower substrate includes a first metal layer, a dielectric layer, a second metal layer, an organic layer, a first insulation layer, a third metal layer, a second insulation layer, a fourth metal layer, a passivation layer and a lower transparent conductive layer which are deposited in sequence on the upper surface of a lower transparent substrate. Embodiments of the present invention also provide a method for producing the LCD panel.