Fine Aluminum Pattern Manufacturing via Water Immersion Oxidation
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Solution Overview
Problem
Existing transparent conductive films, particularly those using ITO, face challenges with high sheet resistance and low light transmittance, making them unsuitable for large-area display devices and solar cells, while metal patterns offer lower costs and resistance but with limited light transmittance and visible touch patterns.
Innovation Solution
A method for manufacturing a fine aluminum pattern by forming an aluminum pattern on a substrate and subsequently immersing it in water to create aluminum oxide on its side surfaces, which increases transmittance and allows for adjustable line width without the need for additional masks or printing plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal patterns are used instead of ITO films, then costs are reduced and resistance is lowered, but light transmittance decreases and touch patterns become visible
Solution Approach 1:
The patent applies local quality by creating aluminum oxide specifically on the side surfaces of the aluminum pattern through controlled water immersion. This selective oxidation maintains the metallic aluminum's high conductivity in the bulk while forming a transparent aluminum oxide layer only where needed (on side surfaces), thus improving light transmittance without compromising electrical conductivity.
Solution Approach 2:
The patent creates a composite structure consisting of aluminum metal combined with aluminum oxide. The aluminum provides low resistance and cost-effectiveness, while the aluminum oxide layer on the side surfaces enhances light transmittance and reduces visibility of touch patterns. This composite approach resolves the contradiction between conductivity and transmittance.
2Illumination intensity
If ITO films are used for transparent conductive films, then light transmittance is maintained, but sheet resistance increases for large-area devices
Solution Approach 1:
The patent replaces expensive ITO films with aluminum, which is cheaper and provides better conductivity. The aluminum pattern is processed through a simple water immersion method to create aluminum oxide, avoiding the need for complex sputtering equipment required for ITO deposition. This substitution reduces both material costs and equipment requirements while maintaining or improving electrical performance.
3Manufacturing precision
If fine metal patterns are manufactured using traditional methods, then line width can be reduced, but additional masks or printing plates are required, increasing process complexity
Solution Approach 1:
The patent employs self-service by allowing the aluminum pattern to undergo spontaneous oxidation when immersed in water. The aluminum naturally reacts with water to form aluminum oxide on its surface, eliminating the need for separate oxidation processes, masks, or printing plates. This self-organizing process automatically creates the desired fine pattern structure with transparent side surfaces.
Solution Approach 2:
The patent controls the oxidation process by adjusting parameters such as water immersion time, temperature, and aluminum pattern dimensions. By changing these parameters, the line width and oxidation extent can be precisely controlled to achieve the desired fine pattern characteristics without requiring additional fabrication steps.
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 method enables the production of a fine aluminum pattern with high transmittance and reduced line width, enhancing the transparency and visibility of touch patterns, while being economically efficient and applicable to various display devices and solar cells.
Implementation Method 1
forming aluminum oxide on at least a portion of the aluminum pattern by immersing the aluminum pattern in water
Data Source
AI summary
The present specification relates to a method for manufacturing a fine aluminum pattern, an aluminum pattern manufactured by the manufacturing method, and a conductive film including the same.