Transflective LCD Color Filter Inkjet Rib Patterning
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Solution Overview
Problem
Existing manufacturing methods for color filters in transflective liquid crystal display devices are complex and costly, with no efficient method to simplify the process while maintaining high yield and achieving uniform color purity across reflective and transmissive areas within a pixel.
Innovation Solution
A manufacturing method using photolithography to form ribs on a base layer, followed by an inkjet technique to create a step-forming layer and coloring layer, simplifying the process and reducing material waste, with the ribs acting as dams to prevent material flow and allow for accurate patterning without high precision requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional photolithography methods are used to form color filters for transflective LCDs, then manufacturing precision can be maintained, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The pixel area is segmented into transmissive and reflective regions with different color filter requirements. The color filter is divided into a first color filter for transmissive areas and a second color filter for reflective areas, allowing different coloring characteristics in different regions. This segmentation enables uniform color purity across both areas while simplifying the overall manufacturing approach.
Solution Approach 2:
Different regions of the color filter are given different local properties: the first color filter in transmissive areas has optimized coloring for forward light, while the second color filter in reflective areas has optimized coloring for reflected light. This local differentiation achieves uniform color purity across the entire pixel area without requiring complex global processing.
2Manufacturing precision
If complex multi-step photolithography processes are used to achieve uniform color purity, then color display quality improves, but productivity decreases
Solution Approach 1:
The color filter manufacturing is segmented into distinct first and second color filter regions that can be processed and optimized independently. This allows for specialized coloring processes for each region without requiring complex coordination between multiple lithography steps, thereby improving manufacturing yield while maintaining color purity uniformity.
Solution Approach 2:
The patent applies preliminary coloring actions to form the first and second color filters before final assembly. By pre-forming the color filters with appropriate coloring characteristics for their respective regions, the need for complex post-processing and multiple lithography steps is eliminated, improving both color purity uniformity and manufacturing productivity.
3Ease of manufacture
If the same color filter is used for both transmissive and reflective areas, then manufacturing process is simple, but color purity becomes non-uniform
Solution Approach 1:
The color filter is segmented into a first color filter for transmissive areas and a second color filter for reflective areas. Each segment is optimized for its specific function, with the first color filter handling forward light and the second color filter handling reflected light. This segmentation maintains manufacturing simplicity while achieving uniform color purity across different pixel regions.
Solution Approach 2:
Different local coloring properties are assigned to different regions: the first color filter in transmissive areas has coloring optimized for forward light transmission, while the second color filter in reflective areas has coloring optimized for reflected light. This local quality differentiation achieves uniform color purity without significantly complicating the manufacturing 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 method reduces manufacturing costs and increases yield by simplifying the process, achieving accurate patterning and uniform color purity across pixels, thereby improving the quality of color display in transflective liquid crystal display devices.
Implementation Method 1
forming a step-forming layer by dripping an optical transmissive material into an area defined by the first and second ribs by means of inkjet technique; and forming a coloring layer by dripping an optical coloring material into an area defined by the first rib by means of ink-jet technique
Implementation Method 2
the ribs acting as dams to prevent material flow and allow for accurate patterning without high precision requirements
Data Source
AI summary
An object of the invention is to accurately and easily manufacture a color filter. A method of manufacturing a color filter comprises: a first step of forming a first rib (220) forming a light shield layer and a second rib (230) having a smaller height than the first rib (220) in pattern on a base layer (1) by means of a photolithography method; a second step of forming a step-forming layer (4) by dripping an optical transmissive material into an area defined by the first and second ribs (220, 230) by means of ink-jet technique; and a third step of forming a coloring layer by dripping an optical coloring material (5) into an area defined by the first rib (220) by means of ink-jet technique after forming the step-forming layer (4).