Transflective LCD Manufacturing Reducing Mask Count
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Solution Overview
Problem
The manufacturing process of transflective LCDs requires more masks than transmission-type LCDs, leading to lower efficiency due to the need for seven masks, which increases complexity and reduces productivity.
Innovation Solution
A manufacturing method for transflective LCDs that reduces the number of masks required by forming a multiple layer on a substrate with a transparent electrode layer and gate metal layer, patterning to create gate and data lines, forming passivation and organic insulating layers, and integrating a reflecting layer to connect data pads with data lines, thereby simplifying the process to use six masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If seven masks are used for manufacturing transflective LCD, then the functionality of both reflection and transmission parts is achieved, but the manufacturing efficiency and productivity are reduced
Solution Approach 1:
The patent combines the formation of gate lines, gate electrodes, gate pads, and data pads into a single patterning step using one mask. This merging of multiple patterning operations into one step reduces the total mask count from seven to six, thereby improving manufacturing efficiency while maintaining the required functionality of both reflection and transmission parts
Solution Approach 2:
The patent designs a multi-functional mask that simultaneously defines gate lines, gate electrodes, gate pads, and data pads in a single patterning operation. This universal mask performs multiple functions that traditionally required separate masks, reducing process complexity and improving productivity without compromising the dual functionality of the transflective LCD
2Manufacturing precision
If seven masks are used for manufacturing transflective LCD, then complete patterning of gate and data structures is achieved, but the process complexity increases
Solution Approach 1:
The patent merges multiple patterning operations into a single step, where one mask simultaneously patterns gate lines, gate electrodes, gate pads, and data pads. This consolidation reduces the number of separate patterning processes from seven to six, thereby reducing process complexity while maintaining complete patterning of all required structures
Solution Approach 2:
The patent segments the mask design into distinct functional regions that define different structures (gate lines, gate electrodes, pads, and data lines) within a single patterning step. This segmentation allows each structure to be properly formed with appropriate dimensions and positions while being created in one unified process, maintaining manufacturing precision without increasing process complexity
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 enhances the manufacturing efficiency of transflective LCDs by reducing the number of masks needed, improving the process efficiency and productivity while maintaining the functionality of both reflection and transmission parts.
Implementation Method 1
forming a multiple layer on a substrate by depositing transparent electrode layer and a gate metal layer sequentially
Data Source
AI summary
A manufacturing method of a transflective LCD comprising forming a multiple layer on a substrate by depositing transparent electrode layer and a gate metal layer sequentially, forming a gate line, a gate electrode, a gate pad forming part and a data pad forming part by patterning the multiple layer, forming a gate insulating layer, forming a semiconductor layer, forming a data line, a source electrode and a drain electrode, forming a passivation layer and an organic insulating layer and forming a gate pad and a data pad by providing contact holes exposing the transparent electrode layer on the gate pad forming part and the data pad forming part, respectively. Accordingly, it is an aspect of the present invention to provide a manufacturing method of a transflective LCD using less masks and a transflective LCD thereof.