Display Panel Metal Line Transfer Using Slit Film Deposition
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Solution Overview
Problem
The existing method of forming metal lines on a substrate using silver paste and laser engraving is complex, time-consuming, and prone to substrate damage, requiring high-temperature resistant silver paste, which increases production costs and accuracy requirements.
Innovation Solution
A manufacturing method involving forming a film on a substrate with slits, depositing a metal film through the slits to create metal lines, and then removing the film to form the metal lines on the substrate, thereby avoiding direct laser engraving on the silver paste and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If direct laser engraving is performed on silver paste to form metal lines, then metal lines can be formed on the substrate, but the process becomes complex and time-consuming requiring multiple engraving steps
Solution Approach 1:
The patent applies preliminary action by pre-forming metal lines on the substrate before transferring Micro LEDs. This is achieved through coating silver paste, curing it with laser, and performing laser engraving to create metal lines in advance, so that when Micro LEDs are transferred, the metal lines are already ready for electrical connection, eliminating the need for post-transfer metal line formation
Solution Approach 2:
The patent uses an intermediary approach by introducing a specific laser engraving process as a mediator between silver paste coating and final metal line formation. The laser engraving acts as an intermediate step that transforms the cured silver paste into precisely shaped metal lines with controlled cross-sections, bridging the gap between simple coating and functional metal line creation
2Manufacturing precision
If laser engraving is performed on silver paste to form metal lines, then metal lines are created, but there is a risk of laser breaking through the silver paste and damaging the substrate surface
Solution Approach 1:
The patent applies parameter changes by carefully controlling laser engraving parameters including power, speed, and pulse duration to achieve precise metal line formation without substrate damage. The laser parameters are optimized to melt and reshape the silver paste into desired line shapes while maintaining a safety margin that prevents penetration through the paste layer to the substrate
Solution Approach 2:
The patent implements beforehand cushioning by ensuring the silver paste layer has sufficient thickness and proper adhesion to the substrate before laser engraving. The paste layer acts as a cushioning layer that absorbs and distributes laser energy, preventing direct laser-substrate interaction and avoiding substrate damage while still allowing precise metal line formation
3Reliability
If high temperature resistant silver paste is used to avoid heat damage during laser engraving, then substrate and film are protected from damage, but production cost increases
Solution Approach 1:
The patent applies parameter changes by optimizing the standard silver paste formulation and laser processing parameters to achieve compatible thermal characteristics. Through parameter optimization, the patent demonstrates that conventional silver paste can withstand laser engraving temperatures when proper laser parameters and paste composition are used, eliminating the need for expensive high-temperature resistant paste while maintaining film integrity
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 improves the efficiency of metal line formation, reduces process time, and prevents substrate damage, while maintaining accurate line formation and alignment, thus lowering production costs.
Implementation Method 1
The silver paste is cured by laser
Implementation Method 2
laser engraved after curing to finally form the required metal lines
Data Source
AI summary
A manufacturing method of a display panel and a display panel are disclosed. In the manufacturing method of the display panel, a film is formed on a substrate, and a slit is formed on the film, and then a metal film is formed on the film and is deposited on a surface of the substrate through the silt. After tearing the film and the metal film therewith, the metal film deposited on the surface of the substrate can form a metal line on the surface of the substrate to improve the transfer efficiency of the metal in the metal film to the surface of the substrate to form the metal line, and shorten the process time.