Thin Film Transistor Array Substrate with Integrated Black Matrix
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Solution Overview
Problem
Conventional methods for manufacturing color LCDs with thin film transistors and color filters on separate substrates are costly, complex, and reduce the panel aperture ratio due to the need for a wide black matrix to prevent light damage, which also complicates the process and increases costs.
Innovation Solution
A thin film transistor array substrate structure with an organic material layer, black matrices, and color filter patterns formed using ink-jet printing and laser ablation, where patterned transparent conductive layers electrically connect to transistors through openings in the black matrices and color filter patterns, simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a black matrix is formed on the color filter's substrate to prevent light from damaging the TFTs, then the TFTs are protected from light damage, but the manufacturing cost, processing time, and manufacturing complexity increase
Solution Approach 1:
The patent combines the black matrix and color filter into a single integrated structure on the same substrate. The black matrix is formed in the non-display area while the color filter patterns are formed in the display area, both on the color filter substrate. This integration eliminates the need for separate black matrix formation processes on different substrates, reducing manufacturing complexity while maintaining TFT protection.
Solution Approach 2:
The color filter substrate serves multiple functions: it acts as the substrate for the color filter patterns, the black matrix, and provides the structural base for mounting the TFT substrate. The integrated structure performs both light filtering and structural support functions simultaneously, reducing the number of separate components and processes needed.
2Reliability
If a black matrix is formed on the color filter's substrate, then light damage to TFTs is prevented, but the panel aperture ratio is reduced due to the need for a wider black matrix to account for alignment errors
Solution Approach 1:
The black matrix is localized to specific non-display areas where TFT protection is needed, rather than being uniformly distributed across the entire substrate. The color filter patterns are precisely positioned in the display area with optimized dimensions, allowing the black matrix to be narrower since alignment errors are minimized through the integrated structure. This local optimization increases the display area while maintaining protection where required.
3Adaptability or versatility
If the conventional COA method is used with 9 processes including 5 array processes and 4 color filter processes, then the color filter on array technique is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges the array substrate and color filter substrate formation processes into a single integrated manufacturing flow. The TFT substrate and color filter substrate are formed simultaneously on separate areas of the same substrate, eliminating the need for separate array process and color filter process sequences. This consolidation reduces the total number of manufacturing steps from 9 to fewer processes, lowering manufacturing cost while maintaining COA functionality.
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 color filter on array (COA) process, reduces costs, and maintains a high panel aperture ratio by using organic materials and precise laser ablation to form uniform openings for electrical connections, facilitating efficient and cost-effective production.
Implementation Method 1
forming a plurality of first openings through the black matrices and portions of the organic material layer by laser ablation
Data Source
AI summary
A thin film transistor array substrate structure. The array substrate structure includes a thin film transistor array substrate, an organic material layer formed thereon, and a plurality of black matrices and color filter patterns disposed on the organic material layer. The invention also provides a method of fabricating the thin film transistor array substrate.