Next-Generation Manufacturing Technologies for the Large Area TFT-LCD Panel

This publication has been discontinued on September 5, 2011.

Introduction

Abstract

The large-area TFT-LCD industry, which has surpassed eight-generation lines and draws investments for 10-generation lines, requires a next-generation manufacturing process, upgraded from the existing processes, as the substrates become larger. This is an effort of the industry to make its existing production process more efficient and reduce TACT time, and thus, cost. The TFT-LCD industry has determined that it is impossible to keep up with the performance and price that the market wants with only a drop in the prices of parts and materials. Therefore, it is investing much in the development of new technologies.

The TFT-LCD panel manufacturing process is divided into the TFT process, the Color Filter process (CF), the Cell process, and the Module process. This report will discuss the TFT Array Patterning process and the C/F manufacturing process, which are currently being developed.

Chapters 3 and 4 introduce next-generation patterning processes that can be applied to the TFT Array process. Furthermore, these chapters discuss 3-Mask Process, which reduced the number of masks used in 4-Mask Process that is currently developed, and Maskless Exposure process that makes it possible to perform the exposure process without masks.

Chapter 5 examines the Color Filter on TFT Array process, which forms the color filter on the TFT array, and Chapters 6 through 11 introduce next-generation C/F manufacturing processes that can substitute for the existing Photo Lithography process to produce the C/F. Moreover, these chapters also discuss the merits and demerits, technical issues and major manufacturers' development trends in Nano-Imprinting, Roll Printing, and Inkjet Printing as well as Dry Film Photo Resist Laser Direct Imaging, and Laser-Induced Thermal Imaging processes.

Table of Contents

1. Introduction

• 1. Overview and Structure

2. Large Area TFT-LCD Panel Market Forecast

• 1. TFT-LCD Market Forecast
• 2. Large Area TFT-LCD Panel Price Trends
  • 1. LCD Monitor Panel Sales Price
  • 2. Notebook Panel Sales Price
  • 3. LCD TV Panel Sales Price
• 3. Next-Generation Manufacturing Technologies in Large Area TFT-LCD
  • 1. Technology Roadmap by Manufacturer - LG Display
  • 2. Technology Roadmap by Manufacturer - Samsung Electronics

3. Mask Manufacturing Process Technology

• 1. TFT-LCD Array Structure
  • 1. Introduction to Mask Process in the TFT- LCD Manufacturing Process
• 2. Slit Mask and Lift-Off
• 3. 3-Mask Process
  • 1. Mask Process - First Stage
  • 2. Mask Process - Second Stage
  • 3. Mask Process - Third Stage
• 4. Comparison among 3-, 4-, and 5-Mask Processe

4. Maskless Patterning Process Technology

• 1. Comparison between Mask and Maskless Processes
• 2. Comparison among Maskless Patterning Technologies
  • 1. Direct Imaging - Digital Micro Mirror-based System
  • 2. Direct Patterning
• 3. Maskless Patterning Technology Implementing DMD Technology

5. Color Filter on TFT Array (COA or COT) Technology

• 1. Introduction to the Color Filter Technology
  • 1. Improvement in Opening Ratio
  • 2. Roles of Black Matrix
• 2. Introduction to the Color Filter on TFT Array Technology
• 3. Expected Effect and Technological Issues

6. Nano-Imprinting Technology

• 1. Introduction to the Nano-Imprinting Technology
• 2. Types of the Nano-Imprinting Technology
  • 1. Soft Lithography
  • 2. NIL(Thermal Imprint)
  • 3. SFIL(UV Imprint)
  • 4. Nano-Imprinting Technology Appropriate to TFT-LCD Panel Manufacturing
• 3. Applications of Nano-Imprinting Technology
  • 1. Reflector in Reflective Mode Panel
  • 2. Wire Grid Polarizer
• 4. Major Panel Manufacturers' Application Trends and Forecast
  • 1. LG Display
  • 2. Samsung Electronics

7. Roll Printing Technology

• 1. Introduction to Roll Printing Technology
• 2. Types of Roll Printing Technology
  • 1. Gravure Offset
  • 2. Reverse Offset
• 3. Technological Issues and Improvement Plans
  • 1. Alignment and Color Mixture
  • 2. Uneven Wear and Foreign Substances on Doctor Blade
  • 3. Cliché, Blanket, and Roll
• 4. Roadmap in Technology Implementation
• 5. Current Conditions in the Development by Manufacturer
  • 1. LG Display
  • 2. Samsung Electronics
  • 3. Mitsumura
  • 4. Toppan

8. Inkjet Printing Technology

• 1. Introduction to Inkjet Printing Technology
  • 1. Applicable Fields of Inkjet Printing Technology
  • 2. Merits of Inkjet Printing Technology
• 2. Technological Issues and Problems
• 3. Current Conditions in the Development by Manufacturer
  • 1. AUO
  • 2. DNP
  • 3. LG Display
  • 4. Samsung Electronics

9. Dry Film Photo Resist Technology

10. Laser Direct Imaging Technology

11. Laser-Induced Thermal Imaging Technology

12. Index

• 1. Table Index
• 2. Figure Index

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