Transflective LCD Jumping Electrode Process

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Solution Overview

Problem

The existing manufacturing process for transflective liquid crystal display devices (LCDs) faces issues such as etching solution penetration, adhesion failure between protrusion patterns and transparent electrodes, and over-etching of substrates, leading to defects and reduced manufacturing yield.

Innovation Solution

The process is modified to form a transparent electrode before the protection layer and protrusions, with a method that includes forming a substrate with defined pixel regions, crossing gate and data lines, thin film transistors, and insulation layers with protrusion patterns in the reflection region, allowing for earlier formation of the transparent electrode and reducing the number of mask processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the transparent electrode is formed after the protection layer and protrusions, then the manufacturing process follows the conventional sequence, but etching solution penetrates the transparent electrode causing adhesion failure and defects

Engineering Contradiction:

Improveadhesion between transparent electrode and substrateVSAvoidetching solution penetration

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The transparent electrode is formed before the protection layer and protrusions are created. This preliminary action allows the transparent electrode to be deposited on a stable surface before subsequent etching processes, preventing etching solution from penetrating underneath and causing adhesion failure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional manufacturing sequence is inverted by forming the transparent electrode earlier in the process rather than later. This reversal of the standard process order eliminates the harmful effect of etching solution penetration while maintaining all necessary functional requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If multiple mask processes are used to form the transparent electrode, protection layer, and protrusions separately, then each layer can be precisely positioned, but the number of manufacturing steps increases leading to higher costs and reduced productivity

Engineering Contradiction:

Improvepositioning accuracy of transparent electrodeVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The formation of the transparent electrode, protection layer, and protrusions is merged into a single integrated process step. By combining these previously separate mask processes into one operation, the patent reduces the total number of manufacturing steps while maintaining precise positioning through the preliminary formation of the transparent electrode.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single manufacturing step serves multiple functions by simultaneously forming the transparent electrode, protection layer, and protrusions. This multi-functional approach eliminates the need for separate processes for each component, thereby reducing manufacturing cycle time and costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the reflective electrode is formed with a transmission hole using conventional processes, then the transmission region is created, but over-etching of the substrate occurs leading to defects

Engineering Contradiction:

Improvetransmission hole formation accuracyVSAvoidsubstrate over-etching

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The transparent electrode is formed in advance before the reflective electrode and transmission hole creation. This preliminary formation provides a protective and stabilizing layer that prevents etching solution from over-etching the substrate during transmission hole formation, while still allowing precise hole creation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The transparent electrode serves as a cushioning layer deposited beforehand to protect the substrate from excessive etching. This prior cushioning prevents substrate damage during the transmission hole formation process while maintaining the required precision for creating the transmission region.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8169571B2Transflective LCD device and method with a jumping electrode formed of the same material as a reflective electrode

Publication Date: 2012.05.01 LG DISPLAY CO LTD

AI summary

A transflective type LCD including: a substrate in which a pixel region having a reflection region and a transmission region are defined; a gate line and a data line crossing each other on the substrate to define the pixel region; a TFT (thin film transistor) formed at the crossing of the gate line and the data line; a transparent electrode formed in the pixel region and connected to a drain electrode of the TFT; a storage electrode formed on the gate line; a reflective electrode formed in the reflection region; and an insulation layer with a protrusion pattern formed in the reflection region, wherein the insulation layer in the reflection region is in between the transparent electrode and the reflective electrode.