Mini-LED Backlight Plate Coating Layout for Accurate Alignment
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Solution Overview
Problem
Current methods for forming passivation coating layers in mini-LED backlight manufacturing either lead to inaccurate alignment due to high reflectivity, causing edge cracking and substrate wastage, resulting in increased production costs.
Innovation Solution
A manufacturing method where a hydrophilic material forms a thin film on specific regions of the substrate, allowing accurate alignment and maximum substrate utilization by preventing the hydrophobic passivation coating from forming on these regions, enabling precise pattern formation and efficient cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passivation coating layers are fully coated on surfaces of substrates to ensure working stability and maximize light utilization, then reflectivity is improved (greater than 80%), but alignment accuracy deteriorates because light is directly reflected and cannot reach metal mark objects for CCD detection
Solution Approach 1:
The patent applies local quality by creating different surface properties in different regions: the display region receives full passivation coating for high reflectivity and device stability, while the non-display region has no passivation coating to allow light transmission for metal mark detection and alignment. This spatial differentiation of coating quality resolves the contradiction between needing high reflectivity for stability and needing light transmission for alignment accuracy.
2Measurement precision
If passivation coating layers are not coated on entire edges of substrates where metal mark objects are disposed to enable accurate alignment, then alignment accuracy is improved, but substrate utilization rate deteriorates causing edge regions to be wasted and production cost to rise
Solution Approach 1:
The patent implements local quality by selectively applying passivation coating only to the display region while leaving the non-display region (edge regions) uncoated. This allows the edge regions to be used for metal mark placement and alignment without sacrificing substrate utilization, as the uncoated regions are precisely where they are needed for alignment functionality rather than being wasted.
3Reliability
If passivation coating layers are fully coated on substrates with relatively high film thickness, then working stability is ensured, but manufacturing precision deteriorates as the passivation coating layers become jagged in cutting regions during cutting, causing edge cracking and peeling off
Solution Approach 1:
The patent applies local quality by restricting passivation coating to the display region only, excluding the cutting regions (non-display regions). This ensures that thick passivation coating provides stability where needed for device operation, while avoiding application in cutting regions where it would cause jagged edges, cracking, and peeling during the cutting process, thereby maintaining manufacturing precision.
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 method ensures accurate alignment and maximum substrate utilization, reducing production costs and preventing edge cracking during the cutting process, while maintaining high reflectivity and optical quality.
Implementation Method 1
adopting a hydrophilic material to form a layer of a thin film on the at least one mark region
Implementation Method 2
coating a hydrophobic material on the entire surface of the side of the substrate to form a passivation coating layer
Data Source
AI summary
A manufacturing method of a mini-LED backlight plate and the mini-LED backlight plate are provided. The manufacturing method of the mini-LED backlight plate includes: providing a substrate, defining at least one display region, defining at least one mark region with metal mark objects in a non-display region, covering a mask on the substrate, exposing the at least one mark region, adopting a hydrophilic material to form a layer of a thin film on the at least one mark region, removing the mask, coating a hydrophobic passivation coating layer on the substrate, exposing the metal mark objects, and aligning by an exposure machine accurately.