Liquid Crystal Display Organic Layer Planarization via Transflective Mask Exposure
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Solution Overview
Problem
The manufacturing of liquid crystal displays is hindered by steps between light blocking and transmission areas, leading to non-uniformity of the liquid crystal layer and resulting in display defects like mura due to the deterioration of liquid crystal spreadability during the injection process.
Innovation Solution
A method involving the use of a mask with transflective parts to control exposure amounts on the organic layer, specifically allowing different exposure levels through the transflective and transmission parts to minimize or eliminate the step between light blocking and transmission areas, thereby improving the uniformity of the liquid crystal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a light blocking member is formed on the substrate, then light blocking function is improved, but a step is generated between light blocking area and transmission area causing non-uniformity of liquid crystal layer
Solution Approach 1:
The patent applies local quality by forming the light blocking member with a tapered structure where the width varies along the thickness direction. The wider upper portion and narrower lower portion create different local geometries that serve different functions: the upper portion provides effective light blocking while the tapered transition reduces step formation, allowing uniform liquid crystal layer formation across the substrate surface.
Solution Approach 2:
The patent resolves the step problem by transitioning from a two-dimensional planar light blocking member to a three-dimensional tapered structure. By controlling the width in the horizontal direction to vary along the thickness direction, the invention creates a gradual transition zone that eliminates abrupt steps, thereby improving liquid crystal layer uniformity while maintaining light blocking effectiveness.
2Object-affected harmful factors
If a light blocking member with large width is formed, then light blocking performance is improved, but the step between light blocking area and transmission area increases deteriorating liquid crystal spreadability
Solution Approach 1:
The tapered structure creates local quality variations where different sections of the light blocking member have different widths at different heights. This allows the upper portion to provide strong light blocking performance while the lower portion provides a gradual transition, preventing liquid crystal spreadability issues without compromising light blocking effectiveness.
3Ease of manufacture
If conventional exposure method is used, then manufacturing process is simple, but non-uniform exposure occurs between light blocking area and transmission area causing mura defects
Solution Approach 1:
The tapered light blocking member creates local geometric variations that affect light exposure distribution. By designing the width to vary along the thickness direction, the structure naturally provides different exposure characteristics in different areas, enabling uniform liquid crystal layer formation through controlled exposure without requiring complex multi-step manufacturing processes.
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 reduces non-uniformity in the liquid crystal layer, preventing mura and enhancing the viewing characteristics of the liquid crystal display by ensuring uniform exposure and planarization of the organic layer.
Implementation Method 1
exposing a convex part of the organic layer to light in areas of the thin film transistor and the data line using a mask including a transflective part formed on the areas of the thin film transistor and the data line
Data Source
AI summary
A method of manufacturing a liquid crystal display includes disposing a gate electrode and a light blocking member on a substrate, disposing a source electrode and a drain electrode on the gate electrode to form a thin film transistor, disposing a data line on the light blocking member, disposing an organic layer on the thin film transistor and the data line, exposing a first convex part of the organic layer to light in a first area corresponding to the thin film transistor during an exposure process, and exposing a second convex part of the organic layer to the light in a second area corresponding to the data line during the exposure process using a mask. The mask includes a first transflective part aligned with the first area and a second transflective part aligned with the second area during the exposure process.