RGBW Color Filter With Nested Transparent Pixels
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Solution Overview
Problem
The RGBW color filter structure faces challenges in maintaining high light transmittance and color mixing quality while reducing production costs and avoiding issues like cell gap mura and color mura, which are exacerbated by the addition of a transparent pixel that is often far from R, G, and B pixels.
Innovation Solution
A color filter design where the transparent pixel layers are integrated within the R, G, and B pixel layers, with columnar layers having controlled height differences and disconnected transparent pixel layers to improve light transmittance and color mixing without increasing production costs, and ensuring cell gaps are less than 0.1 μm to prevent mura.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If transparent pixel layers are added to form RGBW structure, then light transmittance and brightness are improved, but color mixing quality deteriorates when transparent pixels are far from R, G, and B pixels
Solution Approach 1:
The transparent pixel layer is nested within the regions defined by adjacent color pixel layers (R, G, B). The transparent pixel layer is positioned inside the triangular or polygonal regions formed by the intersections of color pixel layer boundaries, ensuring close proximity to all three color pixels for optimal color mixing while maintaining high light transmittance.
Solution Approach 2:
The transparent pixel layer is selectively positioned in specific local regions where color mixing is most critical. By placing transparent pixels within the triangular regions formed by R, G, and B pixel intersections, the structure optimizes local color mixing quality while maintaining overall high light transmittance across the display panel.
2Illumination intensity
If transparent pixel layers are added to form RGBW structure, then brightness is improved, but production costs increase due to additional manufacturing steps
Solution Approach 1:
The transparent pixel layer is formed in the same manufacturing process as the color pixel layers, combining multiple functions into a single integrated structure. The transparent and colored pixel layers are created simultaneously using the same photoresist coating, exposure, and development steps, eliminating additional manufacturing processes and reducing production costs.
Solution Approach 2:
The photoresist layer serves multiple functions: it defines both the color pixel layers (R, G, B) and the transparent pixel layer simultaneously. This multi-functional approach allows the single manufacturing process to produce both colored and transparent pixels, reducing the need for separate production lines or additional processing steps.
3Manufacturing precision
If columnar layers are formed to control cell gaps, then cell gap uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The columnar layers are formed during the same photoresist processing steps as the pixel layers, preparing the cell gap structure in advance. The photoresist pattern that defines pixel boundaries also creates the columnar protrusions that will control cell gap uniformity, eliminating the need for separate cell gap formation processes.
Solution Approach 2:
The formation of pixel layers and columnar layers is merged into a single photoresist processing operation. The same photoresist coating, exposure, and development steps that create the pixel pattern also generate the columnar structures, reducing manufacturing complexity while ensuring precise alignment between pixels and columnar layers for optimal cell gap control.
4Illumination intensity
If transparent pixel layers are positioned far from R, G, and B pixels, then light transmittance is improved, but color mixing efficiency deteriorates
Solution Approach 1:
The transparent pixel layer is nested within the triangular regions formed by the intersections of R, G, and B pixel layer boundaries. This nesting ensures that transparent pixels are positioned in close proximity to all three color pixels, optimizing color mixing efficiency while maintaining high light transmittance through the transparent regions.
Solution Approach 2:
The transparent pixel layer is selectively positioned in specific local regions (triangular intersections of color pixels) where color mixing is most critical. This local positioning strategy optimizes color mixing efficiency in the most important areas while maintaining overall high light transmittance across the display panel.
Data Source
AI summary
A color filter, a display apparatus, and a method for preparing the color filter. The color filter comprises: a substrate, black matrices formed on the substrate; color layers formed on the substrate, wherein the color layers comprise red pixel layers (R), green pixel layers (G), blue pixel layers (B), and transparent pixel layers (W); a planarization layer (OC) formed above the color layers and the black matrices; and columnar layers (PS) formed on the planarization layer (OC) and located above the black matrices. The transparent pixel layers (W) are covered in the red pixel layers (R), the green pixel layers (G) and the blue pixel layers (B) by the red pixel layers (R), the green pixel layers (G) and the blue pixel layers (B), respectively.