Marked Pixel Unit Alignment Detection in LCD Manufacturing
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Solution Overview
Problem
Current liquid crystal display technologies face challenges in accurately determining mis-alignment between color filter films and underlying layers, affecting display quality and product yield due to the difficulty in quickly assessing and correcting mis-alignment issues.
Innovation Solution
A marked pixel unit is introduced, featuring a color filter unit with an alignment opening and a pixel electrode connected through a contact hole, allowing for precise detection of mis-alignment by comparing the location of the top electrode and alignment opening, enabling calibration of the color filter layer pattern to ensure accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a color filter film is applied on an active element array substrate, then the display device achieves color filtering function, but mis-alignment between the color filter film and the underlying layer occurs affecting display quality
Solution Approach 1:
The patent introduces marked pixel units with alignment openings and markers before applying the color filter film. These markers and alignment openings are prepared in advance on the active element array substrate, enabling pre-alignment verification and adjustment before the actual color filter film application, thus preventing mis-alignment issues
2Productivity
If mis-alignment detection is performed quickly, then product yield is improved, but detection precision may be compromised
Solution Approach 1:
The patent creates simplified optical copies or projections of the alignment markers and comparison structures. By using optical projection methods, the complex alignment verification process is transformed into a simplified visual comparison task that can be performed quickly while maintaining high precision through the geometric relationships of the projected images
3Manufacturing precision
If the color filter layer pattern is calibrated precisely, then alignment accuracy is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent introduces intermediate alignment markers and comparison structures as mediators between the color filter layer and the underlying active element array. These intermediate elements serve as reference points that simplify the calibration process by providing clear geometric relationships for alignment verification, reducing the overall process complexity while maintaining high precision
Data Source
AI summary
A marked pixel unit includes at least one active element, a first dielectric layer, a color filter unit, a second dielectric layer, and at least one pixel electrode. The active element includes a source, a gate, and a drain. The first dielectric layer is configured to cover the gate. The color filter unit is disposed above the first dielectric layer, and has an alignment opening. The second dielectric layer is disposed above the active element and the color filter unit, and has a contact hole. The pixel electrode is disposed above the second dielectric layer, and electrically connected to the drain through the contact hole. The contact hole of the second dielectric layer is located outside the alignment opening.