Organic Layer Plasma Concave Patterns LCD Mura
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Solution Overview
Problem
Current methods for reducing the 'mura effect' in liquid crystal displays, such as photolithography, are expensive and limited in producing concave patterns at the nanometer scale, which is necessary for aligning liquid crystal molecules effectively, thereby affecting display quality.
Innovation Solution
A method involving the formation of an organic material layer with a plasma treatment to create concave patterns on the substrate, allowing for the alignment of liquid crystal molecules at different pre-tilt angles, which reduces the 'mura effect' and is cost-effective by enabling nanometer-scale pattern production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photolithography process is used to form concave patterns, then mura effect is eliminated or lowered, but production cost increases and manufacturing precision is limited to micrometer scale
Solution Approach 1:
The patent replaces expensive photolithography masks and processing steps with a self-assembling organic material layer that forms concave patterns through controlled deposition and thermal treatment. The organic layer acts as a disposable, self-organizing structure that eliminates the need for costly photomasks and complex lithography equipment while achieving the desired nanometer-scale concave patterns for liquid crystal alignment.
2Reliability
If photolithography process is used to form concave patterns, then mura effect is eliminated or lowered, but manufacturing precision is limited to micrometer scale
Solution Approach 1:
The patent achieves nanometer-scale precision by changing the physical and chemical parameters of the organic material layer deposition process. By controlling deposition temperature, material composition, and thermal treatment parameters, the organic layer self-assembles into concave patterns with dimensions in the nanometer range (smaller than 1 micrometer), far exceeding the precision limits of conventional photolithography.
3Ease of manufacture
If organic material layer with smooth surface is used, then alignment film can be applied smoothly, but mura effect occurs due to defects
Solution Approach 1:
The patent applies local quality by creating non-uniform concave patterns within the organic material layer. These localized concave regions provide specific alignment sites for liquid crystal molecules, while the overall layer maintains sufficient smoothness for application. The concave patterns are distributed throughout the layer, creating local variations in surface topology that prevent mura effects while preserving global smoothness for 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
The method effectively reduces the 'mura effect' in liquid crystal displays by aligning liquid crystal molecules at different pre-tilt angles, improving display quality while being more cost-efficient than traditional techniques.
Implementation Method 1
a plasma treatment to the surface of the organic material layer is performed to form a plurality of concave patterns on the surface of the organic material layer
Data Source
AI summary
A method of fabricating an active device array substrate is provided. A substrate having scan lines, data lines and active devices formed thereon is provided. Each of the active devices is electrically connected to the corresponding scan line and data line. An organic material layer is formed over the substrate to cover the scan lines, the data lines and the active devices. Then, a plasma treatment is performed to the surface of the organic material layer to form a number of concave patterns. The dimension of each of the concave patterns is smaller than one micrometer. Afterward, pixel electrodes are formed on the organic material layer and each of the pixel electrodes is electrically connected to one of the corresponding active devices.