Integrated LCD Fabrication via Phase Separation
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Solution Overview
Problem
The existing liquid crystal display (LCD) fabrication process is complex and time-consuming due to the separate fabrication and bonding of upper and lower substrates, leading to decreased production yield and increased costs, as well as reduced light transmissivity and contrast ratio caused by light scattering from stepped portions and color filters.
Innovation Solution
A method for fabricating an LCD that integrates the formation of the upper substrate and liquid crystal film with the lower substrate using phase separation and photopolymeric color polymers, eliminating the need for additional substrates and bonding, while forming partition walls to maintain uniform thickness and improve light transmissivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate fabrication and bonding of upper and lower substrates is used, then manufacturing precision can be maintained, but device complexity and fabrication time increase
Solution Approach 1:
The patent merges the upper substrate and lower substrate into a single integrated substrate structure. The liquid crystal layer is formed directly on the lower substrate, eliminating the need for separate substrate fabrication and bonding processes. This integration maintains manufacturing precision while significantly reducing device complexity and fabrication time.
Solution Approach 2:
The lower substrate serves multiple functions: it acts as both the lower substrate and provides the base for liquid crystal layer formation. The color filter layer is integrated into the lower substrate structure, making it a multi-functional component that eliminates the need for a separate upper substrate.
2Stability of the object's composition
If separate substrate bonding is used, then structural stability can be maintained, but productivity decreases
Solution Approach 1:
By merging the upper and lower substrates into one integrated structure, the patent eliminates the bonding process entirely. The liquid crystal layer is formed directly on the lower substrate through photopolymerization, which maintains structural stability while dramatically increasing productivity by removing a time-consuming fabrication step.
Solution Approach 2:
The liquid crystal monomer is pre-coated on the lower substrate before photopolymerization. This preliminary action allows the liquid crystal layer to form in-situ during the bonding process, eliminating the need for subsequent liquid crystal injection and alignment steps, thereby increasing productivity.
3Adaptability or versatility
If stepped portions and color filters are present, then device functionality is achieved, but light transmissivity decreases
Solution Approach 1:
The patent applies local quality by creating a recessed region in the lower substrate at the pixel electrode position. This local modification allows the liquid crystal layer to be formed thinner in this specific area, reducing light scattering from stepped portions while maintaining the necessary display functionality. The color filter layer is also locally optimized to minimize interference with light transmission.
Solution Approach 2:
The patent introduces a vertical dimension solution by creating a recessed region in the lower substrate. This dimensional change allows the liquid crystal layer to be positioned at a lower height, reducing the step height between the liquid crystal layer and surrounding areas, thereby minimizing light scattering and improving light transmissivity while maintaining display functionality.
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 simplifies the fabrication process, enhances yield, reduces costs, and improves light transmissivity and contrast ratio by simultaneously forming the upper substrate and liquid crystal film during the fabrication of the lower substrate, maintaining uniform thickness and image quality.
Implementation Method 1
a liquid crystal compound comprising a reactive mesogen and a binder monomer is coated on the lower substrate, and then photo-exposed to form an upper substrate and a liquid crystal film
Implementation Method 2
providing a compound containing a liquid crystal and a photopolymeric color polymer on the lower substrate; photo-exposing a boundary of a color filter region to form a partition wall from the photopolymeric color polymer
Data Source
AI summary
A LCD and a fabrication process is presented. An upper substrate is coincidently formed with a red, a green and a blue color filters using phase separation. A compound containing a photopolymeric color filter resin and a liquid crystal are coated on an array substrate and then photopolymerized after formation of the array substrate. A seed layer may be provided on the substrate before the compound is applied. Polymerization of the color filter resin permits simultaneous formation of the upper, color filter substrate and liquid crystal layer.