Color Filter Roller Coating Apparatus Eliminates Exposure Steps
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Solution Overview
Problem
The existing process for manufacturing color filter substrates is complex, time-consuming, and costly due to the need for successive exposure and development processes, which also results in high energy consumption and expensive mask plate usage.
Innovation Solution
A coating apparatus featuring a roller with openings matching the shape of color pixel units, combined with a resin-pressing device that coats and cures light-filter resin directly onto the substrate without exposure or development, reducing the need for mask plates and photoresist, and allowing for the formation of color filter units in predetermined areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If successive exposure and development processes are used to form color filters, then the color filter substrate can be manufactured with precise patterning, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent extracts and eliminates the exposure and development processes from the conventional color filter manufacturing process. By using a roller with openings that directly transfer light-filter resin in a predetermined pattern onto the substrate, the complex photochemical processes are removed, leaving only the essential coating and curing steps.
Solution Approach 2:
The roller with openings serves as a physical template or copy of the desired color filter pattern. Instead of using optical masks and photochemical reactions to create patterns, the roller directly copies the predetermined pattern onto the substrate through mechanical contact and resin transfer.
2Manufacturing precision
If successive exposure and development processes are used, then color filters can be formed with precise patterns, but the manufacture duration increases
Solution Approach 1:
The roller with openings is pre-configured with the exact pattern needed for color filter formation. This preliminary preparation of the roller eliminates the need for real-time exposure and development steps, allowing direct transfer of the predetermined pattern onto the substrate in a single coating operation.
Solution Approach 2:
The coating process continues uninterrupted by eliminating the exposure and development steps that would otherwise pause production. The roller continuously transfers resin and forms patterns in one continuous motion, maintaining productive action throughout the manufacturing process.
3Manufacturing precision
If conventional exposure and development processes are employed, then color filters can be manufactured, but resin consumption and energy consumption increase
Solution Approach 1:
The patent removes the energy-intensive exposure and development processes from the manufacturing sequence. By using direct roller coating with predetermined openings, the process eliminates the need for exposure machines and developing machines, significantly reducing energy consumption while maintaining pattern accuracy.
4Manufacturing precision
If mask plates are used for patterning, then precise color filter patterns can be achieved, but manufacturing costs increase due to mask plate expenses
Solution Approach 1:
The roller with openings serves as a reusable physical copy of the desired pattern, replacing expensive mask plates. Once the roller is manufactured with the correct opening pattern, it can be used repeatedly without the need for additional mask plates, eliminating the recurring cost of mask plate production and replacement.
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 simplifies the manufacturing process, saves time and costs, reduces energy consumption, and improves yield and quality by eliminating the need for exposure and development steps, while minimizing resin usage and extending the lifespan of equipment.
Implementation Method 1
a resin-pressing device, wherein the roller is provided with a plurality of openings on its external surface, the openings have a shape identical to a shape of color pixel units of the substrate to be coated, the roller is further provided with a cavity communicating with the openings, the cavity is configured for housing resin, and the resin-pressing device is configured for forcing the resin within the cavity out through the openings
Data Source
AI summary
A coating apparatus for manufacturing a color filter substrate, comprising a roller and a resin-pressing device, the roller is provided with a plurality of openings on its external surface, the openings have a shape identical to a shape of color pixel units of the substrate to be coated, the roller is further provided with a cavity communicating with the openings, the cavity is configured for housing resin; the resin-pressing device is configured for forcing the resin within the cavity out through the openings. Also disclosed is a process for manufacturing a color filter substrate, comprising: providing a substrate, on which a predetermined area forming patterns for color filter units is provided; and coating the predetermined area of the substrate with the coating apparatus to form the patterns for color filter units.