Pattern Formation Using Adhesive Film for Chemical-Free Cleaning
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Solution Overview
Problem
The existing patterning methods for flat panel displays, such as photolithography and patterning apparatus using a printing roller, face high manufacturing costs and complex processes due to the use of masks and liquid chemicals, which complicate the cleaning and increase environmental impact.
Innovation Solution
A patterning apparatus utilizing a printing plate with a predetermined pattern and a sticky film to remove unused printing material physically, eliminating the need for chemical cleaners and simplifying the process by leveraging the adhesive strength of the sticky film to remove excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography or printing roller patterning is used, then pattern formation is achieved, but the process becomes costly and time-consuming due to masks and liquid chemicals
Solution Approach 1:
The invention extracts and eliminates the harmful liquid chemical cleaning step from the patterning process. By using a self-adhesive patterning material that can be directly applied and then cleanly removed with adhesive tape, the method removes the need for chemical solvents and complex cleaning equipment, thereby improving productivity while maintaining pattern formation precision
Solution Approach 2:
The invention changes the physical-chemical parameters of the patterning material by using a self-adhesive material with controlled adhesion properties. This material adheres to the substrate during patterning but can be easily removed with adhesive tape, transforming the cleaning process from a chemical-intensive operation to a simple mechanical removal process
2Manufacturing precision
If liquid chemicals are used for patterning, then pattern formation is achieved, but environmental cleanup requirements and maintenance costs increase
Solution Approach 1:
The invention converts the potentially harmful liquid chemical cleaning process into a beneficial dry cleaning method using adhesive tape. The adhesive tape not only removes the patterning material but also captures any residual particles, transforming a harmful chemical process into an environmentally friendly mechanical removal process that eliminates waste liquid disposal requirements
Solution Approach 2:
The invention employs disposable adhesive tape instead of reusable chemical cleaning systems. The tape is a simple, inexpensive, single-use component that eliminates the need for expensive chemical disposal infrastructure and environmental compliance systems, thereby reducing both environmental impact and maintenance costs
3Manufacturing precision
If masks and liquid chemicals are used in patterning, then pattern formation is achieved, but process complexity and cleanup requirements increase
Solution Approach 1:
The invention extracts and removes the complex liquid chemical cleaning equipment from the patterning system. By using adhesive tape for material removal, the process eliminates the need for chemical storage tanks, pumping systems, filtration equipment, and waste treatment facilities, thereby significantly reducing device complexity while maintaining pattern formation precision
Solution Approach 2:
The invention replaces the chemical-based patterning and cleaning system with a mechanically-based approach using adhesive tape. This substitution eliminates complex chemical delivery and waste management systems, replacing them with simple mechanical tape application and removal operations, thereby reducing overall 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 approach reduces environmental impact, decreases maintenance and cleanup costs, and improves yield by eliminating the need for chemical cleanup and simplifying the cleaning process, while maintaining high precision in pattern formation.
Implementation Method 1
a removing unit (250) having a sticky film (256) so as to remove the unused printing material of the printing plate (230)
Data Source
AI summary
An apparatus and method for forming a pattern is provided, to improve a yield by decreasing the tack time for cleaning a printing plate. The apparatus includes a stage; a substrate loaded on the stage; a printing plate positioned on the stage; a printing unit that prints a printing material patterned by a predetermined pattern of the printing plate on the substrate; and a removing unit having a film so as to remove the unused printing material of the printing plate.