Alignment Film Printing Plate with Variable Bump Sizes
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Solution Overview
Problem
Current alignment film printing plates with uniformly large circular bumps on the bottom sheet face challenges in maintaining accuracy at the boundary area due to excess liquid material, leading to irregular splashing and reduced precision in printing.
Innovation Solution
The alignment film printing plate features a bottom sheet with smaller first circular bumps on the edge and larger second circular bumps in the center, where the first bumps have a diameter of ⅓ or ¼ of the second bumps, made of organic photoresist material, to control the quantity of liquid alignment material and improve boundary area printing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniformly large circular bumps are used on the bottom sheet, then the alignment film can be coated effectively in the central area, but the boundary area printing accuracy deteriorates due to excess liquid material and irregular splashing
Solution Approach 1:
The bottom sheet is designed with two types of circular bumps: first circular bumps with a first diameter in the boundary area and second circular bumps with a second diameter (larger than the first) in the central area. This local differentiation allows the boundary area to use smaller bumps that hold less liquid alignment material, reducing irregular splashing and improving printing accuracy, while the central area uses larger bumps for effective coating.
2Manufacturing precision
If large circular bumps are used to ensure adequate liquid material in the center, then coating effectiveness is maintained, but boundary control accuracy deteriorates
Solution Approach 1:
The bottom sheet differentiates bump sizes by location: smaller first circular bumps at the boundary for precise control, and larger second circular bumps in the center for adequate material supply. This local quality approach ensures both boundary control accuracy and central coating effectiveness without compromising either.
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 design reduces irregular splashing and enhances printing accuracy at the boundary area by managing the liquid alignment material effectively between the bumps, improving the overall precision of the alignment film printing process.
Implementation Method 1
coating an organic photoresist material on the backing protection layer and using a mask to subject the organic photoresist material so coated to exposure and development
Data Source
AI summary
A method forming an alignment layer for a liquid crystal display device including: attaching a transfer film on a printing roll, the transfer film including a convex portion having first-sized halftone dots and second-sized halftone dots; positioning a substrate on a printing table; providing aligning solution on an anilox roll using a doctor roll; and transferring the aligning solution on the anilox roll to the transfer film while moving the printing table and rotating the printing roll, and then coating the aligning solution on the substrate to thereby form an alignment layer on the substrate.