NCD Liquid Crystal Display Microcavity Structural Integrity
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Solution Overview
Problem
In the manufacturing process of nanocrystal display (NCD) liquid crystal displays, the light blocking layer is often damaged during the ashing process to form microcavities, and the absence of a roof layer leads to microcavity damage due to its weakness in thermal processes, necessitating an improved method to prevent damage and enhance structural integrity.
Innovation Solution
The implementation of a light blocking layer enclosed by passivation layers and the omission of a roof layer, where the partition formation part supports microcavities to reinforce resistance against external impacts, ensuring the light blocking layer is not damaged during the ashing process and providing structural support without a roof layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a roof layer is used to support microcavities, then structural support is provided, but the roof layer is damaged during thermal processes such as ashing
Solution Approach 1:
The patent removes the roof layer from the microcavity structure, eliminating the component that is vulnerable to thermal damage during ashing processes. The microcavities are supported alternatively by the partition formation parts and the surrounding structure, without requiring a separate roof layer.
Solution Approach 2:
The patent employs a sacrificial layer that is intentionally designed to be temporary and removable. This sacrificial layer is used during manufacturing to define the microcavity space, then completely removed through ashing to create the final microcavity structure without a permanent roof layer.
2Ease of manufacture
If the light blocking layer is exposed during manufacturing, then it can be formed to block light, but it is damaged during the ashing process to form microcavities
Solution Approach 1:
The light blocking layer is formed before the ashing process that removes the sacrificial layer. By establishing the light blocking layer in advance, the patent ensures that light blocking functionality is achieved while protecting the layer from subsequent thermal damage through proper process sequencing and the elimination of the vulnerable roof layer.
Solution Approach 2:
The patent removes the roof layer that was previously used to protect the light blocking layer during manufacturing. Instead, the light blocking layer is directly exposed and integrated with the partition formation parts, eliminating the intermediate protective structure that caused manufacturing issues.
3Strength
If partition formation parts are used to support microcavities without a roof layer, then structural integrity is enhanced, but additional manufacturing steps are required
Solution Approach 1:
The patent combines the partition formation parts with the structural support function previously performed by the roof layer. The partition formation parts are designed to serve dual purposes: defining the microcavity boundaries and providing structural support, thereby eliminating the need for a separate roof layer and reducing overall device complexity.
Solution Approach 2:
The partition formation parts are designed to perform multiple functions simultaneously: they define the microcavity structure, provide structural support, and eliminate the need for a separate roof layer. This multi-functionality reduces the number of manufacturing steps and simplifies the overall device architecture.
Data Source
AI summary
A liquid crystal display includes a substrate; a thin film transistor on the substrate; a pixel electrode connected to the thin film transistor; a first insulating layer facing the pixel electrode; a plurality of microcavities each defined between the pixel electrode and the first insulating layer and including a liquid crystal injection hole exposing an inside of the microcavity; a liquid crystal layer including liquid crystal molecules, in the microcavities; a light blocking layer between adjacent microcavities; and a passivation layer member enclosing the light blocking layer.