Color Filter Partitions for LCD Color Isolation
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Solution Overview
Problem
In liquid crystal display (LCD) manufacturing, the alignment of pixel electrodes and color filters on different panels leads to alignment errors, causing color mixture and reduced color reproducibility due to improper partition formation and varying ink heights during the Inkjet printing process.
Innovation Solution
A method involving the formation of partitions on a single substrate with a thin film transistor, where a color filter is placed between partitions, and organic layers are used to reduce step sizes and ensure uniform height, with a second organic layer covering the partitions to maintain a uniform cell gap and prevent light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the partition height is increased to prevent color mixture, then color isolation is improved, but a step is generated where ink is not filled, causing protrusions and depressions in the passivation layer that reduce process margin
Solution Approach 1:
The partition structure is divided into two distinct parts: a first partition formed during the initial process to provide color isolation, and a second partition formed later to planarize the surface. This segmentation allows each partition to serve its specific function without compromising the other, resolving the contradiction between color isolation and surface flatness.
Solution Approach 2:
The first partition is formed in advance during the color filter formation process to establish color isolation boundaries. This preliminary action ensures that color mixture is prevented from the outset, while subsequent processes can then focus on addressing the surface step issue with the second partition.
2Manufacturing precision
If the partition height is large to prevent color mixture, then color isolation is improved, but protrusions and depressions of the passivation layer are formed, reducing process margin for light blocking member and photosensitive film
Solution Approach 1:
The partition system is segmented into a first partition for color isolation and a second partition for surface planarization. The second partition specifically addresses the protrusion and depression issues by filling in the surface irregularities created by the first partition, thereby maintaining process margin for subsequent manufacturing steps.
Solution Approach 2:
The second partition acts as an intermediary element between the first partition and the passivation layer. It mediates the surface irregularities by providing an additional layer that compensates for the steps and protrusions, ensuring a more uniform surface for subsequent processes.
3Ease of manufacture
If pixel electrodes and color filters are disposed on different display panels, then manufacturing is simplified, but alignment error occurs between pixel electrodes and color filters
Solution Approach 1:
The patent merges the pixel electrodes and color filters onto the same display panel (COA structure). This combining eliminates the alignment errors that occur when these components are on separate panels, as they are formed simultaneously in the same process environment with consistent reference frames.
Solution Approach 2:
The display panel serves multiple functions by integrating both the pixel electrode formation and color filter formation processes. This multi-functional approach allows both components to be manufactured together on a single substrate, ensuring precise alignment while maintaining manufacturing efficiency.
Data Source
AI summary
The present invention relates to a display device and a method for manufacturing the display device. The display device includes at least one partition formed on a lower display panel. A color filter may fill a region defined by the partitions. A first upper passivation layer is formed on the color filter, and a second upper passivation layer is formed on the first upper passivation layer and the partitions such that the LCD structure is planarized. In the display device, the height of the partition is sufficiently high to prevent mixing of the colors of neighboring pixel filters, and the process margin of the spacer and the light blocking member may be ensured. The partitions can be formed with multiple layers having different widths such that the mixture of colors between the neighboring pixels may be prevented, and the color reproducibility may be increased.