Reflective Metal Surface Texturing via Nitrogen Insertion
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Solution Overview
Problem
Conventional methods for creating a rugged reflective surface in reflective LCDs are complex and not suitable for mass production, requiring mechanical casting or spacers to form a rough surface for the reflective metal film.
Innovation Solution
A method involving the alteration of metal lattice atomic cells with nitrogen atoms to create an uneven surface, using a substrate with a first metal layer and a layer of aluminum nitride, which can be deposited by reactive sputtering, allowing for the formation of a reflective metal film with a rugged surface without the need for mechanical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical casting or spacers are used to form a rough surface for the reflective metal film, then a rugged reflective surface is achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent replaces mechanical casting methods and spacer-based approaches with a chemical deposition process. Aluminum nitride is deposited directly onto the metal layer through atomic layer deposition or chemical vapor deposition, where the nitrogen atoms chemically interact with the metal surface to create the rugged texture. This eliminates the need for mechanical molds, spacers, or complex casting equipment.
Solution Approach 2:
The patent changes the deposition parameters of the aluminum nitride layer to control the formation of the rugged surface. By adjusting deposition temperature, pressure, and precursor flow rates, the nitrogen atoms can be controlled to create specific surface roughness patterns directly during deposition, rather than requiring post-processing mechanical steps.
2Manufacturing precision
If mechanical casting or spacers are used to form a rough surface, then a rugged reflective surface is achieved, but production time and labor costs increase
Solution Approach 1:
The patent merges the surface texturing step with the aluminum nitride deposition step into a single process. The rugged surface formation is integrated into the deposition process itself, eliminating separate mechanical texturing operations and reducing the total number of manufacturing steps.
Solution Approach 2:
The patent replaces time-consuming mechanical casting and spacer removal operations with a direct chemical deposition process that forms the rugged surface in-situ during aluminum nitride deposition, significantly reducing production time and eliminating labor-intensive steps.
3Ease of manufacture
If a smooth reflective plate is used, then manufacturing is simple, but mirror reflective phenomenon occurs and reflectivity is reduced
Solution Approach 1:
The patent uses chemical deposition to create the rugged surface pattern directly on the aluminum nitride layer, replacing complex mechanical texturing processes. The chemical reaction between nitrogen atoms and the metal surface during deposition naturally forms the desired rough morphology without requiring mechanical intervention.
Solution Approach 2:
The patent creates a composite structure consisting of the metal layer combined with the aluminum nitride layer. The aluminum nitride serves dual functions: as a protective overcoat and as a template for forming the rugged surface pattern through its deposition process, combining multiple functions into a single material layer.
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 simplifies the production of reflective LCDs by creating a rugged surface through the insertion of nitrogen atoms, reducing production time and labor costs while maintaining reflectivity and adhesion, making it more suitable for mass production.
Implementation Method 1
The atomic cells in the lattice are altered in the presence of nitrogen atoms, and due to the existence of nitrogen atoms, it makes the surface of the metal layer uneven because of twisted atomic cells in the metal lattice caused by inner repulsion once nitrogen is added into the metal layer.
Implementation Method 2
using a substrate with a first metal layer and a layer of aluminum nitride, which can be deposited by reactive sputtering
Data Source
AI summary
A method of manufacturing a reflecting substrate in a liquid crystal display device is disclosed, comprising the steps of: (a) providing a substrate having a first metal layer, wherein the first metal layer is formed with at least one soft metal or the alloys thereof; and (b) forming an aluminum nitride layer on the first metal layer. The method of the present invention is capable of forming a rugged, shining, reflective layer on a transflective, or a reflection type TFT LCD with simple steps and low cost.