Parallax Barrier Formation on LCD Substrates
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Solution Overview
Problem
Existing methods for manufacturing 3D and dual-view liquid crystal display devices face issues such as bonding failures, increased costs, and reduced productivity due to the complexity of forming parallax barrier patterns, particularly when using metallic films or thick resin layers, which affect the substrate strength and display quality.
Innovation Solution
A method involving bonding mother substrates to form a cell substrate, then forming a parallax barrier layer on the outer surface of one substrate before cutting out panels, allowing for simultaneous formation and alignment of the parallax barrier layer across multiple panels, reducing the number of manufacturing steps and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a glass substrate with a parallax barrier is bonded to a completed LCD, then the parallax barrier pattern can be formed, but bonding failures occur at a constant rate and productivity deteriorates
Solution Approach 1:
The parallax barrier layer is formed on the color filter substrate before the LCD assembly is completed and before final panel cutting. This preliminary formation allows the barrier pattern to be created while the substrate is still in a convenient state for processing, avoiding later bonding operations that cause failures and productivity loss.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: first forming the parallax barrier layer on the color filter substrate, then bonding substrates to form cell substrates, and finally cutting into individual panels. This segmentation allows each operation to be optimized independently, eliminating the need for problematic post-assembly bonding.
2Object-affected harmful factors
If a metallic film is used for the parallax barrier pattern, then light-shielding is achieved, but the number of manufacturing steps increases due to separate resist pattern forming and removing
Solution Approach 1:
The black matrix pattern and parallax barrier pattern are both formed using the same metallic film material and the same etching process. This multi-functional approach allows a single manufacturing sequence to accomplish what previously required separate processes, reducing step count while maintaining effective light-shielding for both functions.
Solution Approach 2:
The formation of the black matrix pattern and parallax barrier pattern is merged into a single simultaneous etching process. By using the same metallic film layer for both patterns and etching them together, the manufacturing process is simplified without compromising the light-shielding performance of either feature.
3Length of moving object
If a thick resin layer is used to adjust distance between the liquid crystal layer and parallax barrier layer, then the distance can be controlled, but substrate strength is reduced and manufacturing becomes difficult
Solution Approach 1:
Instead of using a thick resin layer to achieve the required distance, the invention changes the parameter of substrate thickness itself. By controlling the thickness of the color filter substrate, the distance between the liquid crystal layer and parallax barrier layer is precisely controlled while maintaining adequate substrate strength for manufacturing and handling.
Data Source
AI summary
A method of manufacturing a display device according to one aspect of the present invention is a method of manufacturing a display device including a liquid crystal interposed between a CF substrate and a TFT substrate that are opposed to each other, the method including the steps of: bonding the CF substrate and the TFT substrate each having a mother substrate shape to form a cell substrate from which at least one panel is to be cut out; forming, after formation of the cell substrate, a parallax barrier layer for separating a display image on an outer side of the cell substrate at a side of one of the CF substrate and the TFT substrate; and dividing, after formation of the parallax barrier layer, the cell substrate into at least one panel.