Transflective LCD Passivation Layer Bumps

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Solution Overview

Problem

The manufacturing process of conventional transflective LCD panels is complex and costly due to the need for two photo mask processes to form reflective and transmissive areas, which complicates the formation of the organic and metal layers.

Innovation Solution

A method involving a first substrate with an uneven electrode layer and a second passivation layer with bumps, made of amorphous silicon nitride, which provides reflection characteristics and simplifies the process by using only one photo mask to form reflective areas, reducing the complexity and cost of manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If two photo mask processes are used to form reflective and transmissive areas, then the manufacturing precision of the organic and metal layers is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveprecision of organic and metal layer formationVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the formation of reflective and transmissive areas into a single photo mask process. The organic layer is formed with a specific pattern that directly defines both reflective areas (where metal layer will be deposited) and transmissive areas (where organic layer remains) in one step, eliminating the need for separate photo mask processes for each layer.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The organic layer is formed in advance with a predetermined pattern before metal layer deposition. This preliminary patterning of the organic layer serves as a template that guides subsequent metal layer formation, allowing the reflective area pattern to be established before the metal deposition step occurs.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If two photo mask processes are used to form reflective and transmissive areas, then the manufacturing precision is improved, but the loss of time increases

Engineering Contradiction:

Improveprecision of reflective and transmissive area formationVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges multiple photo mask processes into a single integrated process. By forming the organic layer pattern in one photo mask step that simultaneously defines both reflective and transmissive areas, the manufacturing cycle is shortened while maintaining the required precision for area differentiation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The organic layer is preliminarily formed with the complete pattern information for both reflective and transmissive areas before subsequent metal layer processing. This preliminary action consolidates multiple patterning steps into one, reducing the overall manufacturing time.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple photo mask steps are used, then the manufacturing precision is improved, but the ease of manufacture deteriorates

Engineering Contradiction:

Improveprecision of layer formationVSAvoidease of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent simplifies the manufacturing process by combining multiple photo mask steps into a single step. The organic layer is formed with a unified pattern that defines both reflective and transmissive areas, eliminating the need for separate photo mask processes and making the overall manufacturing easier to execute.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The organic layer serves multiple functions: it acts as both the final organic layer structure and as a patterning template for the metal layer deposition. This multi-functionality eliminates the need for separate photo mask processes, simplifying the manufacturing process while maintaining precision.

Inventive Principle:

Principle #6Universality (Multi-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 approach simplifies the manufacturing process and reduces costs by eliminating the need for multiple photo mask steps, while enhancing the reflective characteristics of the transflective LCD panel through the use of a second passivation layer with bumps, improving light reflection and panel performance.

Implementation Method 1

the second passivation layer has a reflection characteristic, and the second passivation layer has a plurality of bumps at an inmost side thereof

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS7768607B2Transflective liquid crystal display panel and method for manufacturing substrate thereof

Publication Date: 2010.08.03 INNOLUX CORP

AI summary

An exemplary transflective liquid crystal display panel (2) includes a first substrate (21) with a glass base (210), a second substrate (22) opposite to the first substrate, a liquid crystal layer (23) between the first and second substrates, and an insulating layer (211), a first passivation layer (212), a first electrode layer (213), and a second passivation layer (216) successively disposed at an inner side of the glass base. The first electrode layer has an uneven surface (2131), the second passivation layer is provided only at reflective areas of the transflective liquid crystal display panel, the second passivation layer has a reflection characteristic, and the second passivation layer has a plurality of bumps (2161) at an inmost side thereof.