Mold with Stair-Shape Pattern Parts for LCD Color Filters
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Solution Overview
Problem
The existing manufacturing processes for display devices, such as LCDs, are complex and time-consuming due to the need for multiple photolithography steps and mask usage when forming color filters and photosensitive layers with varying thicknesses.
Innovation Solution
A mold with a supporting frame featuring pattern forming parts of different depths and an organic layer removing part is used to simplify the process, allowing for the formation of color filters and photosensitive layers with varying thicknesses without the need for multiple masks, by using a series of molds with stair-shaped pattern forming parts and light-blocking films to define the pattern and remove excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple photolithography processes including slit masking and halftone masking are used to form color filters and photosensitive layers with different thicknesses, then the manufacturing precision is improved, but the device complexity and manufacturing time increase significantly
Solution Approach 1:
The mold is divided into multiple pattern forming parts (first, second, third pattern forming parts) with different depression depths, allowing simultaneous formation of color filters and photosensitive layers with different thicknesses in a single pressing operation. This segmentation of the mold structure eliminates the need for multiple photolithography processes while maintaining precise thickness control for each layer type.
2Manufacturing precision
If multiple photolithography processes are used to form patterns with varying thicknesses, then the manufacturing precision is improved, but the productivity decreases due to increased processing time
Solution Approach 1:
The invention merges multiple pattern forming operations into a single mold pressing step. The mold contains first, second, and third pattern forming parts with different depression depths that simultaneously form color filters and photosensitive layers with different thicknesses in one operation, eliminating the need for sequential slit masking, halftone masking, and exposure processes.
Solution Approach 2:
The mold is pre-designed with pattern forming parts having predetermined depression depths corresponding to the required thicknesses of color filters and photosensitive layers. This preliminary configuration of the mold structure allows direct formation of multi-thickness patterns without requiring subsequent thickness adjustment processes, thereby improving manufacturing efficiency.
3Manufacturing precision
If multiple masks and exposure steps are used to form color filters and photosensitive layers, then the manufacturing precision is improved, but the loss of time increases due to repeated masking and exposure operations
Solution Approach 1:
The invention extracts and eliminates the masking and exposure steps from the manufacturing process by using a mold-based pressing method. The pattern forming parts of the mold directly transfer the required patterns onto the color filter and photosensitive layers through mechanical pressing, removing the time-consuming mask alignment and light exposure operations while maintaining pattern accuracy.
4Ease of manufacture
If a simple mold structure is used, then the ease of manufacture is improved, but the manufacturing precision of multi-thickness patterns deteriorates
Solution Approach 1:
The mold employs pattern forming parts with locally differentiated depression depths - the first pattern forming part has a first depression depth for color filters, while the second and third pattern forming parts have a second depression depth greater than the first for photosensitive layers. This local variation in mold geometry enables precise control of different pattern thicknesses within an otherwise simple mold structure.
Data Source
AI summary
A mold for a display device, comprises a supporting frame; the supporting frame comprising at least one depressed pattern forming part on a first side of the supporting frame, and an organic layer removing part which is formed on a circumference of the pattern forming part, the pattern forming part depressed regions of different depths, the mold having light-blocking and light-transmitting portions corresponding to certain of the depressed pattern forming parts.