Laser-Formed Black Matrix for LCD Substrates
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Solution Overview
Problem
The existing manufacturing process for liquid crystal display (LCD) devices is inefficient due to the complexity and cost of the photolithography-based black matrix formation, which increases process time, cost, and reduces productivity, and can result in light leakage and black defects.
Innovation Solution
A method using a laser beam to form a light shielding region on a transparent substrate or resin layer, eliminating the need for multiple mask processes and creating a flat surface for color filters, thereby reducing the number of steps and materials required, and preventing light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a black matrix is formed using photolithography process, then light shielding function is achieved, but manufacturing complexity and process time increase
Solution Approach 1:
The patent replaces the photolithography process (chemical/optical system) with a laser direct writing process (optical/thermal system). The laser beam directly writes the black matrix pattern on the resin layer, eliminating the need for photoresist, masks, and chemical development steps, thus reducing manufacturing complexity while maintaining light shielding function
Solution Approach 2:
The patent changes the material state and processing parameters by using a laser beam to locally heat and carbonize the resin layer directly where needed. This transforms the resin from a uniform transparent state to a patterned black matrix state through controlled thermal parameters, simplifying the manufacturing process
2Manufacturing precision
If multiple mask processes are used to form black matrix and color filters, then patterning precision is achieved, but productivity decreases
Solution Approach 1:
The patent merges the black matrix formation and color filter formation into a single integrated process. The laser beam writes both the black matrix boundaries and color filter patterns in one operation, eliminating multiple separate mask processes and significantly improving productivity while maintaining patterning precision
Solution Approach 2:
The patent performs preliminary pattern definition by using the laser beam to create the black matrix boundaries first, which then serve as guides for subsequent color filter formation. This preliminary action establishes the structural framework before filling in color details, streamlining the overall manufacturing process
3Reliability
If photolithography process is used, then black matrix pattern is formed, but black defects occur reducing product yield
Solution Approach 1:
The patent replaces the photolithography system with a laser direct writing system that offers better control over pattern formation. The laser process eliminates common photolithography defects such as residue, incomplete patterns, and alignment errors, thereby improving product yield by reducing black defects
Solution Approach 2:
The patent changes the processing parameters from chemical exposure (photolithography) to thermal/optical exposure (laser writing). This parameter change allows for more precise and reliable pattern formation, eliminating defects caused by incomplete photoresist removal or alignment errors, thus improving both pattern quality and product yield
4Reliability
If black matrix is formed by photolithography, then light shielding is achieved, but material costs increase
Solution Approach 1:
The patent eliminates expensive photolithography materials such as photoresist, masks, and chemical developers by using a laser process that requires no consumable materials. The only material needed is the resin layer itself, which is heated and carbonized by the laser, significantly reducing material costs while maintaining light shielding function
Solution Approach 2:
The patent replaces the expensive photolithography equipment and consumable materials with a more economical laser writing system. The laser process uses minimal materials (just the resin layer) compared to the extensive materials required for photolithography, reducing overall manufacturing cost
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 significantly reduces processing time and cost, improves product yield by eliminating black defects, and allows for a more efficient fabrication of LCD substrates with a light shielding means that prevents light leakage.
Implementation Method 1
irradiating a laser beam having a predetermined power onto the transparent substrate to form a light shielding region
Implementation Method 2
irradiating a laser beam having a predetermined power onto the transparent substrate to form a light shielding region
Data Source
AI summary
A method of fabricating a substrate for a liquid crystal display device includes: disposing a transparent substrate on a stage of a laser apparatus; irradiating a laser beam having a predetermined power onto the transparent substrate to form a light shielding region in the transparent substrate surrounding first to third light transmitting regions; and forming a color filter layer including red, green and blue sub-color filters respectively in the first to third light transmitting regions, wherein boundaries of the red, green and blue sub-color filters correspond to the light shielding region.