Unveiling the Production Process of Bibuke Company's IPS High-Definition LCD Display Screens

Today, with the continuous innovation in display technology, IPS high-definition LCD screens have become the favorite of many consumers due to their outstanding performance, such as wide viewing angles and accurate colors. As a leader in this field, Bibuke Company is renowned for its IPS screens of superior quality. Today, we will delve into the manufacturing process of Bibuke Company's IPS high-definition LCD screens. Please provide the text you would like translated.

IPS (In-Plane Switching, 平面转换) technology was introduced by Hitachi in 2001. Its essence is based on TFT technology, but it solves the viewing angle problem of traditional LCD panels with a unique molecular arrangement. Bibuke Company has continuously delved into this fundamental technology and developed IPS high-definition LCD displays with unique advantages.

Complex and precise manufacturing process 

The manufacturing of IPS high-definition LCD displays is a precise process involving hundreds of steps and completed in a highly clean environment. It is mainly divided into four major stages. 

Front-end Array Process 

The core objective of this stage is to build a TFT array that can control each pixel switch on the glass substrate, as well as data lines and scan lines. First, ultra-high-precision glass substrates enter the production line and undergo strict cleaning and surface treatment to remove any particles, impurities, and contaminants, laying the foundation for the subsequent processes. 

Then, thin film deposition is carried out. Bibuke Company uses advanced technologies such as PECVD (Plasma Enhanced Chemical Vapor Deposition) and sputtering to deposit multiple layers of films on the glass substrate. First, a gate metal layer is formed to constitute the scan lines and TFT gate electrodes; then, a gate insulating layer is deposited, typically using silicon nitride or silicon dioxide materials; followed by a semiconductor layer, using amorphous silicon or polycrystalline silicon to form the TFT channel; then, an ohmic contact layer, n⁺-doped amorphous silicon (a - Si), is deposited; subsequently, the source/drain metal layer is formed to construct the data lines and TFT source/drain electrodes; finally, a transparent conductive layer (ITO) is deposited at the end of the data line to form the pixel electrode (Pixel Electrode). 

The photolithography process is the key环节 of the front-end array process. First, photoresist is evenly applied to the deposited films, then through a mask with precise circuit patterns, using specific wavelengths of ultraviolet light to expose the photoresist, causing changes in the light-sensitive areas. Next, the film is developed using a chemical solution to wash away the exposed (or unexposed, depending on the type of photoresist) areas, transferring the mask pattern onto the photoresist. Then, dry etching (plasma) or wet etching (chemical solution) is used to remove the unprotected film layers, precisely replicating the required circuit graphics, and finally removing the remaining photoresist. This series of film deposition, photolithography, etching, and stripping steps needs to be repeated 4 to 7 times, ultimately constructing a complete array circuit on the glass substrate containing millions of TFTs and their interconnection lines. 

Front-end Color Filter Process 

This stage aims to produce a color filter on another glass substrate containing red, green, blue primary color pixels and a black matrix (Black Matrix). Similarly, the substrate is first subjected to strict cleaning to ensure its cleanliness. 

When making the black matrix, chromium or resin materials are deposited first, then the pattern is defined using the photolithography process (coating - exposure - development), and finally etched to form the black matrix (BM). The black matrix is used to separate pixels and prevent color mixing, significantly improving the display contrast. 

The production of color filter films mostly adopts the pigment dispersion method. First, the specified color (red, green, blue) of the photoresist is spun-coated on the substrate, then exposed through the corresponding R/G/B mask, developed to remove the unexposed areas, forming single-color pixel graphics, and then the photoresist is baked and solidified. This process needs to be repeated separately for red, green, and blue colors, ultimately covering the entire effective display area. Then, a transparent protective film (Overcoat) is coated on the color filter array to level the surface and protect the color resist. Finally, a transparent conductive ITO film is溅射沉积 on the protective layer as the common electrode (Common Electrode), in IPS technology, this step is sometimes performed on the array substrate side. In addition, the photolithography process is used to precisely fabricate tiny photosensitive resin columns (Photo Spacers) on the CF substrate, which serve as column-shaped spacers to maintain a precise and uniform cell gap when the two substrates are aligned. 

Mid-stage cell formation process (Cell Process) 

In this stage, the TFT substrate (with pixel electrodes) and the CF substrate (with common electrodes) are precisely aligned and bonded, and liquid crystal material is injected between the two substrates to form a sealed liquid crystal cell. First, a layer of polyimide (PI) is coated on the surfaces of the TFT substrate (pixel electrodes) and the CF substrate (common electrodes) as an alignment film. This can be achieved using transfer printing (Offset Printing) or inkjet printing (Inkjet Printing) techniques. Then, the PI film is baked and cured, and a specific direction and intensity of felt (nylon or cotton) is used for rubbing (Rubbing) to form tiny grooves on the PI surface, providing a pre-tilt angle (Pretilt Angle) and initial alignment direction (Alignment Direction) for the liquid crystal molecules. Subsequently, a controlled number of spherical spacers (Ball Spacers, sometimes used together with Photo Spacers or as an alternative) are precisely sprayed above the CF substrate, and a circle of UV-curable sealant is applied in the edge area of the substrate to achieve final sealing. In a vacuum environment, the TFT substrate and CF substrate are precisely aligned up and down with extremely high precision, which is a crucial step and requires position accuracy controlled at the micrometer level. After bonding, the two substrates are tightly pressed together by external atmospheric pressure, and then UV light is irradiated to preliminarily cure the frame sealant (UV light can pass through the glass), and finally liquid crystal droplets are injected and the vacuum bonding is completed. 

Post-stage module process (Module Process) 

This stage involves assembling the completed liquid crystal cells (Cells) from the cell formation process with the backlight unit (Backlight Unit, BLU), driving circuits, and other functional components into a complete display module. It includes chip bonding operations, followed by aging tests and functional tests to ensure the product meets high-quality standards. 

Advantages of Bibuke's IPS Display Screens 

Bibuke's IPS high-definition liquid crystal display screens have many advantages thanks to the above precise manufacturing processes. In terms of dynamic picture display, due to the innovative horizontal switching molecular arrangement of IPS screens, the response speed is faster, the image has no ghosting, the color does not shift, and the dynamic picture performance far exceeds that of traditional screen liquid crystals. Its wide viewing angle characteristic is particularly prominent, with viewing angles of 178 degrees up, down, left, and right, basically eliminating visual "dead zones", and the color performance will not be affected or show color drift from any angle. In terms of screen durability, the physical structure of the IPS hard screen is stable, there is no ghosting or water marks when touching, the molecule recovery speed is fast, and it has significant advantages over ordinary soft screens. In terms of color performance, Bibuke's IPS display screens can rival professional colorists and can truly present images, and are widely used in fields with extremely high color requirements, such as TV program production. 

With the continuous development of display technology, Bibuke will continue to innovate and explore in the manufacturing process of IPS display screens, providing consumers with more high-quality and high-performance display products, and promoting the display industry to a new height.