Sacrificial Layer Method for Display Electrode and Cavity Formation
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Solution Overview
Problem
The manufacturing process of liquid crystal display apparatuses is complex and lacks efficiency, requiring multiple steps and materials to form electrodes and cavities, which complicates the production and reliability of the final product.
Innovation Solution
A method involving the formation of a sacrificial layer with a polymer resin containing an acid-dissociative crosslink and a photoacid generator, followed by the deposition of a conductive layer and the creation of a photo pattern to etch and remove the sacrificial layer, simplifying the process by allowing concurrent removal of the photo pattern and sacrificial layer, and exposing the substrate to light to facilitate the disconnection of crosslinks for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to form electrodes and cavities separately, then manufacturing precision is maintained, but device complexity increases and productivity decreases
Solution Approach 1:
The patent combines the electrode formation and cavity formation processes into a single integrated process. The sacrificial layer is patterned to define both the electrode regions and the cavity regions simultaneously, eliminating the need for separate processing steps. This merging of operations directly reduces process complexity and improves manufacturing efficiency.
Solution Approach 2:
The sacrificial layer is formed and patterned before the electrode material is deposited. This preliminary action allows the cavity structure to be pre-defined, and subsequent electrode deposition automatically conforms to this pre-established pattern, simplifying the overall manufacturing sequence and reducing the number of steps required.
2Loss of time
If multiple separate steps are used for forming electrodes and cavities, then manufacturing precision is maintained, but loss of time increases
Solution Approach 1:
The patent merges multiple sequential operations (cavity formation, electrode formation, alignment) into a single patterned sacrificial layer process. By defining both cavity and electrode patterns in one step, the manufacturing cycle time is dramatically reduced while maintaining precision through the inherent alignment of the patterned structure.
Solution Approach 2:
The sacrificial layer is segmented into different regions (electrode regions and cavity regions) within a single continuous layer. This segmentation allows different functional areas to be defined simultaneously without requiring separate processing steps, thereby reducing time loss while preserving the precision needed for each distinct region.
3Reliability
If conventional materials are used for sacrificial layer, then ease of manufacture is maintained, but reliability decreases due to difficulty in removal
Solution Approach 1:
The patent uses a photoresist material for the sacrificial layer that can be selectively removed through photochemical parameter changes. By exposing the photoresist to specific wavelengths of light, the material undergoes chemical changes that enable easy removal without affecting other components, thereby improving reliability while maintaining ease of manufacture.
Solution Approach 2:
The patent replaces mechanical or chemical etching methods for sacrificial layer removal with a photochemical removal process. Instead of using harsh chemicals or mechanical means that could damage surrounding structures, light exposure selectively decomposes the photoresist material, enabling clean removal and improving overall device reliability.
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 manufacturing process, improves the reliability of the display apparatus by reducing the complexity of forming cavities and electrodes, and potentially lowers manufacturing costs by enabling concurrent removal of the sacrificial and photo patterns, thus enhancing the overall quality and efficiency of the display apparatus production.
Implementation Method 1
a polymer resin including an acid-dissociative crosslink; and a photoacid generator
Implementation Method 2
exposing the substrate to light to facilitate the disconnection of crosslinks for easy removal
Data Source
AI summary
A method of manufacturing a display apparatus and a display apparatus manufactured by using (utilizing) the method.