Capillary Coating Device for Color Filter Pattern Definition
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Solution Overview
Problem
Current methods for manufacturing color filters, such as exposure development, pigment dispersion, electro deposition, ink-jet printing, stripe coating, and discontinuous micro-patch coating, face issues like low raw material utilization, complex processes, high equipment costs, limited pattern variability, and difficulty in producing large panels with complex patterns.
Innovation Solution
A capillary coating device and method utilizing capillary tubes, holders, and traversing mechanisms to apply coating materials directly to substrates, leveraging capillary forces to form continuous or discontinuous liquid films and patterns, allowing for precise control over pattern generation and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If exposure development method is used for color filter manufacturing, then pattern definition is achieved, but raw material utilization is low and process complexity increases
Solution Approach 1:
The patent extracts and eliminates the exposure and development steps from the traditional coating process. By using a maskless direct-write coating approach, the pattern is defined directly during coating without requiring separate exposure and development processes, thereby eliminating material waste associated with these steps while maintaining pattern definition accuracy.
Solution Approach 2:
The patent performs pattern definition preliminarily through digital mask design and programmed nozzle positioning before the actual coating occurs. The coating material is deposited only where needed based on pre-calculated patterns, preventing material waste before it occurs rather than removing excess material afterward.
2Manufacturing precision
If dyeing method is used for color filter manufacturing, then absorptive layer patterning is achieved, but process complexity and equipment cost increase
Solution Approach 1:
The patent merges the coating and patterning operations into a single direct-write process. The maskless direct-write coating system combines the functions of material deposition and pattern formation into one step, eliminating the need for separate dyeing, exposure, and development equipment and processes.
Solution Approach 2:
The patent introduces a digital pattern file as an intermediary between the design stage and physical coating. This digital intermediary guides the automated nozzle system to deposit material precisely where needed, replacing the need for physical masks and complex dyeing equipment while achieving the same patterning function.
3Adaptability or versatility
If ink-jet printing method is used for color filter manufacturing, then pattern variability is improved, but productivity decreases due to sequential droplet deposition
Solution Approach 1:
The patent implements continuous material flow from the coating head to the substrate during the coating process. The viscous coating material is supplied continuously through capillary action and pressure control, eliminating the intermittent droplet-by-droplet deposition of ink-jet printing while maintaining precise pattern control through programmed nozzle movement.
Solution Approach 2:
The patent uses hydraulic pressure control and capillary action to regulate the flow of coating material from the reservoir through the nozzle. This fluid pressure-based control system enables continuous material supply with precise flow rate control, achieving both high productivity and pattern accuracy without the limitations of sequential droplet ejection.
4Productivity
If stripe coating method is used for color filter manufacturing, then coating efficiency is improved, but pattern flexibility and variability are limited
Solution Approach 1:
The patent employs a dynamic, programmable coating system where the nozzle position, movement speed, and deposition parameters can be adjusted in real-time based on the desired pattern. This dynamic control allows the same coating head to produce various patterns (stripes, patches, complex geometries) by changing digital instructions rather than requiring different physical coating tools.
Solution Approach 2:
The patent controls coating parameters such as material viscosity, flow rate, nozzle-to-substrate distance, and scanning speed to optimize both coating efficiency and pattern flexibility. By adjusting these parameters programmatically, the system achieves high productivity while adapting to different pattern requirements without sacrificing either efficiency or versatility.
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
Enhances raw material utilization, reduces manufacturing costs, improves pattern variability, and enables efficient production of large panels with complex patterns, overcoming limitations of existing methods by providing precise control over coating operations.
Implementation Method 1
A capillary coating device and method utilizing capillary tubes, holders, and traversing mechanisms to apply coating materials directly to substrates, leveraging capillary forces to form continuous or discontinuous liquid films and patterns
Data Source
AI summary
A discontinuous capillary coating device is disclosed. A discontinuous capillary coating device. At least one capillary tube is filled with a coating material. At least one coating substrate receives a liquid coating film. At least one capillary tube holder holds the capillary tube, guiding movement of the capillary tube. At least one traversing mechanism drives the capillary tube holder or coating substrate to move.