Liquid Crystal Display Ribs and Spacers Single Mask Formation
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Solution Overview
Problem
The manufacturing process for Vertical Alignment (VA) mode liquid crystal display (LCD) devices is complex and time-consuming, requiring multiple mask processes, which increases costs and reduces productivity due to the separate formation of ribs and spacers.
Innovation Solution
A method for simultaneously forming ribs and spacers on the common electrode using a photosensitive layer exposed through a mask with specific transmitting and blocking portions, allowing for the reduction of mask processes and simplification of the manufacturing process, while maintaining the cell gap between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mask processes are used to form ribs and spacers, then the structural integrity and function of each component is ensured, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent combines the formation of ribs and spacers into a single mask process. The mask pattern is designed to simultaneously define both rib and spacer regions, allowing both structures to be formed in one exposure and development cycle. This merging eliminates the need for separate mask processes while maintaining the structural integrity and functional requirements of both ribs and spacers.
Solution Approach 2:
The single mask pattern serves multiple functions: it defines the rib structures for liquid crystal alignment, defines the spacer structures for cell gap maintenance, and differentiates between them through specific pattern design. This multi-functional mask approach replaces multiple specialized masks, reducing manufacturing complexity while ensuring both components meet their respective functional requirements.
2Manufacturing precision
If multiple mask processes are used for forming ribs and spacers, then precise positioning and dimensions are achieved, but productivity decreases and costs increase
Solution Approach 1:
The patent merges multiple positioning operations into a single mask alignment process. By designing the mask pattern to include both rib and spacer definitions in one coherent structure, the patent achieves precise positioning for both components simultaneously, eliminating repeated alignment operations and significantly improving manufacturing efficiency.
3Adaptability or versatility
If separate processes are used for ribs and spacers, then each component can be optimized independently, but the overall manufacturing time and cost increase
Solution Approach 1:
The patent combines rib and spacer formation into one process step while maintaining the ability to independently optimize their designs. The mask pattern allows for independent dimensioning and positioning of rib and spacer features, preserving design flexibility and adaptability while eliminating the time penalty of sequential manufacturing.
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 the number of mask processes required, simplifies the manufacturing process, prevents common electrode disconnection, and enables the production of high-quality LCDs with wide viewing angles by forming multi-domains with symmetrical properties within the liquid crystal arrangement.
Implementation Method 1
forming first patterns and a second pattern by developing the exposed photosensitive layer
Data Source
AI summary
A liquid crystal display device includes first and second substrates spaced apart from and facing each other, gate and data lines on an inner surface of the first substrate and crossing each other to define a pixel region, a thin film transistor adjacent to the crossing of the gate and data lines, a pixel electrode in the pixel region and including a plurality of slits, an island pattern over the gate line, a black matrix on an inner surface of the second substrate, the black matrix corresponding to the gate line, a color filter layer on the black matrix, a common electrode on the color filter layer, a plurality of ribs on the common electrode corresponding to the pixel electrode; and a spacer on the common electrode corresponding to the black matrix.