Single-Substrate Liquid Crystal Display Manufacturing Process
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Solution Overview
Problem
Current liquid crystal display manufacturing processes require two substrates, increasing complexity, weight, thickness, and costs, as well as prolonging the manufacturing time.
Innovation Solution
A method to manufacture a liquid crystal display using a single substrate, where a gate member and common electrode line are formed on the substrate, with a gate insulating layer, semiconductor, and data member, followed by multiple passivation layers and color filters, and contact holes are etched using photolithography and dry etching with fluorocarbon gas to expose electrodes and connect them simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two substrates are used in the liquid crystal display manufacturing process, then the display device can be assembled with proper structure, but the manufacturing complexity, weight, thickness, and costs increase
Solution Approach 1:
The patent merges multiple components that were traditionally manufactured on separate substrates into a single substrate structure. Specifically, the gate member, common electrode line, semiconductor member, data member, color filters, and connecting members are all integrated on one substrate, eliminating the need for a second substrate and reducing manufacturing complexity while maintaining device functionality
Solution Approach 2:
The single substrate serves multiple functions simultaneously: it acts as the base for the gate member, common electrode line, semiconductor member, data member, color filters, and connecting members. This multi-functional substrate design replaces the traditional two-substrate approach, reducing overall device complexity while achieving the same structural goals
2Reliability
If two substrates are used in the liquid crystal display manufacturing process, then the display device can be assembled with proper structure, but the weight and thickness of the display device increase
Solution Approach 1:
By combining all necessary components (gate member, common electrode line, semiconductor member, data member, color filters, and connecting members) onto a single substrate, the patent eliminates the weight of the second substrate and associated bonding materials, thereby reducing the overall weight of the display device while maintaining structural integrity
3Reliability
If two substrates are used in the liquid crystal display manufacturing process, then the display device can be assembled with proper structure, but the thickness of the display device increases
Solution Approach 1:
The patent reduces display device thickness by integrating all components onto a single substrate rather than using two separate substrates. The stacked arrangement of layers (gate member, gate insulating layer, semiconductor member, data member, color filters, passivation layers, and connecting members) on one substrate eliminates the thickness contribution of the second substrate and intermediate bonding layers
4Reliability
If two substrates are used in the liquid crystal display manufacturing process, then the display device can be assembled with proper structure, but the manufacturing time and costs increase
Solution Approach 1:
By manufacturing all components on a single substrate using a unified process flow, the patent eliminates the time required for separate substrate manufacturing, intermediate handling, and bonding operations. The integrated approach allows simultaneous formation of multiple components through sequential layer deposition and patterning steps on one substrate, significantly reducing total manufacturing time
Solution Approach 2:
The patent performs preliminary actions by forming the gate member, common electrode line, and other components on the single substrate before final assembly steps. The gate insulating layer, semiconductor member, and data member are prepared in advance on the same substrate, enabling streamlined subsequent processing and reducing overall manufacturing time compared to coordinating multiple substrate processes
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 approach simplifies the manufacturing process, reduces weight, thickness, and costs, while shortening the manufacturing time by integrating multiple components on a single substrate, thereby enhancing efficiency and reducing complexity.
Implementation Method 1
The first and second contact holes are formed by etching the second passivation layer, the conductor layer, the first passivation layer, and the gate insulating layer in a single step using a photolithography process
Implementation Method 2
The removing of the exposed portions of the first passivation layer and the gate insulating layer and the exposed portion of the second passivation layer may be performed by dry etching
Data Source
AI summary
A manufacturing method includes forming a gate member and a common electrode line on a substrate. A gate insulating layer is formed on the gate member and the common electrode line. A semiconductor member and a data member are formed on the gate insulating layer. A first passivation layer is formed on the semiconductor member and the data member. A plurality of color filters is formed on the first passivation layer. A conductor layer and a second passivation layer are formed on the plurality of color filters. A first contact hole exposes a common electrode. A second contact hole exposes the drain electrode. The first and second contact holes are formed by a photolithography process. A pixel electrode connected to the drain electrode is formed through the first contact hole. A connecting member connected to the common electrode line and the common electrode is formed through the second contact hole.