Vertical Alignment Layer Pretilt Angle Control via Single Mask Scan Exposure
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Solution Overview
Problem
The existing methods for manufacturing vertical alignment layers in liquid crystal displays require multiple masks, which complicates the alignment film manufacturing process and increases costs.
Innovation Solution
A method involving a mask with light blocking and transmitting parts is used to alternate pretilt angles in alignment layers on substrates, reducing the number of masks needed by using a scan exposure apparatus to apply light pulses in a specific pattern, allowing for the formation of vertical alignment layers with different pretilt angles, thereby simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the light alignment method, then the vertical alignment layer can be formed with different pretilt angles, but the manufacturing process becomes complex and costs increase
Solution Approach 1:
The single mask is segmented into light blocking parts and light transmitting parts, allowing different regions of the alignment layer to receive different light exposure patterns. This segmentation enables the formation of multiple pretilt angles (different in the first direction and second direction) using a single mask structure, eliminating the need for multiple separate masks while maintaining precise control over the alignment characteristics in different areas.
2Manufacturing precision
If multiple masks are used in the light alignment method, then the vertical alignment layer can be formed with different pretilt angles, but manufacturing costs increase
Solution Approach 1:
The invention merges the functions of multiple masks into a single integrated mask structure. The single mask contains both light blocking parts and light transmitting parts that work together to create the required different pretilt angles in different directions. This consolidation reduces the number of mask components needed, simplifies the manufacturing process, and lowers overall manufacturing costs while maintaining the capability to achieve precise pretilt angle control.
3Device complexity
If a single mask with light blocking and transmitting parts is used, then the number of masks is reduced, but the alignment process requires precise substrate movement and rotation control
Solution Approach 1:
The invention employs periodic action through controlled substrate movement and rotation during the light alignment process. The substrate is moved in the first direction and rotated to specific angles, allowing the single mask with light blocking and transmitting parts to sequentially expose different regions of the alignment layer. This periodic movement and rotation pattern enables the single mask to perform the work of multiple masks, achieving different pretilt angles while maintaining ease of operation through automated, repeatable positioning sequences.
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 the complexity and cost of manufacturing by minimizing the number of masks required, improving the efficiency of the alignment process and enhancing the display's viewing angle and contrast ratio.
Implementation Method 1
The exposure apparatus provides first light pulses to the first areas while the substrate moves in the first direction to form a pretilt angle in the first areas. The exposure apparatus provides second light pulses to the second areas while the substrate moves in the first direction to form a pretilt angle in the second areas.
Data Source
AI summary
A method of forming a vertical alignment layer includes disposing a substrate on a stage, the substrate including an alignment layer, the alignment layer includes first areas and second areas alternately arranged in a first direction, and disposing a mask over the substrate, the mask including light blocking parts and light transmitting parts that correspond to the first areas. An exposure apparatus disposed over the mask provides light to the first areas when the substrate moves in the first direction to form a pretilt angle in the first areas. The stage is rotated so that the light transmitting parts correspond to the second areas, and the exposure apparatus provides light to the second areas when the substrate moves in the first direction to form a pretilt angle in the second areas. The pretilt angle formed in the first areas is different from the pretilt angle formed in the second areas.