Soft Mold Patterning for Color Filter Array Substrates
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Solution Overview
Problem
The existing methods for fabricating color filter array substrates in liquid crystal display devices are costly and complex, requiring multiple photolithography processes that increase manufacturing time and costs, and result in inefficient light transmission due to the need for multiple masks and expensive equipment.
Innovation Solution
A method using a soft mold with grooves and projections to form black matrices, color filters, overcoat layers, and ribs without photolithography, allowing for simultaneous patterning of thin films and reducing the need for expensive exposure equipment, thereby simplifying the process and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography process is used for thin film patterning, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the photolithography process from the thin film patterning sequence, replacing it with a direct soft mold contact method. This removes the complex mask alignment, exposure, and development steps while maintaining patterning precision through the soft mold's groove structure that directly transfers patterns to the resin layer.
Solution Approach 2:
The patent replaces the optical-mechanical photolithography system with a purely mechanical soft mold contact system. The soft mold's elastic deformation and contact pressure mechanically transfer the groove patterns to the resin layer, substituting the complex optical exposure system with a simpler mechanical pressing operation.
2Manufacturing precision
If multiple photolithography processes are used for color filter fabrication, then precise color filter patterns can be formed, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple separate photolithography patterning steps into a single soft mold contact process. The soft mold contains integrated groove structures that simultaneously define the patterns for black matrices, color filters, and other elements in one contact operation, eliminating sequential processing steps and significantly improving manufacturing efficiency.
Solution Approach 2:
The soft mold serves multiple functions: it acts as a patterning template, a pressure application device, and a alignment reference all in one component. The single soft mold structure can pattern different color filters (R, G, B) and black matrices simultaneously, making the process universally applicable to all color filter fabrication needs without requiring multiple specialized equipment setups.
3Manufacturing precision
If conventional photolithography equipment is used, then patterning can be performed, but manufacturing cost increases due to expensive equipment
Solution Approach 1:
The patent employs a disposable soft mold that can be easily manufactured at low cost and replaced if needed. The soft mold, made from silicone rubber or similar materials, is a simple elastomeric component that can be produced through conventional molding techniques, eliminating the need for expensive photolithography equipment while maintaining patterning capability through the mold's groove structure.
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 reduces manufacturing costs and time by eliminating the need for photolithography, enhances precision, and improves light transmission by allowing for a smoother overcoat layer and adjusted liquid crystal arrangement directions, leading to better picture quality and reduced manufacturing complexity.
Implementation Method 1
a soft mold which has a projected part formed at an area corresponding to the overcoat layer, and a groove formed at an area corresponding to the rib that projects from the overcoat layer
Data Source
AI summary
A fabricating method of a color filter array substrate includes the steps of forming a black matrix on a substrate, forming red, green, blue color filters on the substrate on which the black matrix is formed, forming an overcoat layer including a white color filter on the substrate on which the red, green, and blue color filters are formed, aligning a flat panel soft mold to the overcoat layer; and smoothing the overcoat layer using the flat panel soft mold.