Dual-Surface Patterning via Selective Light Transmittance
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Solution Overview
Problem
The existing methods for manufacturing conductive films with patterned layers on both surfaces of a substrate are inefficient due to the need for multiple steps and potential pattern deviation caused by substrate expansion and contraction, particularly when using resin composition layers with IRGACURE OXE-02, which results in unwanted light exposure across surfaces.
Innovation Solution
A method is developed to control light absorption properties of the polymerization initiator and the substrate, allowing for patternwise light irradiation on both surfaces with specific wavelength requirements to prevent light transmission and exposure, reducing the number of steps and ensuring pattern accuracy on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If patternwise light irradiation is carried out from both surfaces of the substrate to form patterned layers on both surfaces, then the number of manufacturing steps is reduced, but light from one surface reaches the other surface causing unwanted exposure of the resin composition layer
Solution Approach 1:
The substrate is designed with different optical properties for different regions: the first main surface region has high light transmittance to allow patternwise irradiation, while the second main surface region has low light transmittance to block unwanted light. This local differentiation of optical properties enables simultaneous patterning on both surfaces without mutual interference.
Solution Approach 2:
The substrate acts as an intermediary element that selectively transmits and blocks light between the two resin composition layers. By controlling the light transmittance of different substrate regions, it mediates the light irradiation process to achieve independent patterning on each surface while maintaining the benefit of simultaneous processing.
2Adaptability or versatility
If resin composition layers containing IRGACURE OXE-02 are disposed on both surfaces of the substrate, then patterned layers can be formed on both surfaces, but light irradiated from one surface reaches the other surface causing the resin composition layer on the other surface to be exposed
Solution Approach 1:
The substrate exhibits spatially varying light transmittance properties: high transmittance in the first main surface region enables effective light delivery to the resin composition layer on that side, while low transmittance in the second main surface region prevents light from reaching and exposing the resin composition layer on the opposite side, thereby eliminating unwanted exposure.
3Manufacturing precision
If individual steps are carried out for each surface of the substrate to form patterned layers, then pattern accuracy is maintained, but the number of steps increases which is not industrially preferable
Solution Approach 1:
The patent combines the patterning operations for both surfaces into a single integrated process. By applying resin composition layers to both surfaces and performing patternwise light irradiation simultaneously, the manufacturing process achieves both surfaces' patterning in one operation, reducing the total number of steps while maintaining precision through the substrate's selective light transmittance control.
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 enables the convenient and efficient manufacturing of laminates with patterned layers on both surfaces of a substrate, reducing the number of steps and minimizing pattern deviations, thereby improving the manufacturing process for touch panel sensors and touch panels.
Implementation Method 1
a polymerization initiator and the following compound X or composition Y; a step B including a step B-1 of irradiating one layer for forming a layer to be plated with light in a patternwise fashion
Implementation Method 2
controlling light absorption properties of a polymerization initiator and a substrate, and a wavelength of light to be irradiated
Data Source
AI summary
A method for manufacturing a laminate containing patterned layers to be plated includes a step of preparing a laminate having a substrate having two main surfaces, and layers for forming a layer to be plated, respectively disposed on two main surfaces of the substrate and containing a polymerization initiator, a step of irradiating a layer for forming a layer to be plated in the laminate with light in a patternwise fashion under a predetermined requirement, and a step of removing non-light irradiated regions in the layers for forming a layer to be plated, thereby forming patterned layers to be plated on two main surfaces of the substrate. Also set forth are a touch panel sensor, a touch panel, a laminate containing patterned layers to be plated, and a metal layer-containing laminate.