Dynamic Pattern Transfer Printing for Variable Paste Line Pitch

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Solution Overview

Problem

Current pattern transfer printing methods for high viscosity paste in solar PV and electronics industries are limited by the need for contact between the source and receiving substrates, which restricts flexibility in pattern adaptation and increases the complexity of achieving precise pattern transfer.

Innovation Solution

A dynamic pattern transfer printing system utilizing a laser scanner to illuminate a source substrate with trenches arranged in a first pattern, releasing printing paste onto a receiving substrate, which is moved to create a second pattern different from the first, allowing for non-contact printing and pattern modification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the source substrate and receiving substrate are kept stationary during printing, then the paste pattern can be precisely transferred, but the deposited pattern cannot be changed during printing, reducing flexibility and throughput

Engineering Contradiction:

Improvepaste pattern transfer precisionVSAvoidpattern change flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The receiving substrate is made movable relative to the source substrate during the printing process. The system allows the receiving substrate to be moved in real-time, enabling the deposited pattern to differ from the source pattern while maintaining precise paste transfer. This dynamic adjustment capability resolves the contradiction between precision and flexibility.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If the source substrate and receiving substrate are kept stationary during printing, then the printing process is simple to control, but the throughput is reduced due to inability to change patterns

Engineering Contradiction:

Improveprinting process control simplicityVSAvoidprinting throughput

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system introduces controlled movement of the receiving substrate during printing, enabling multiple pattern variations from a single source substrate. This increases productivity by allowing pattern changes without requiring multiple stationary substrates or repeated printing processes, while the movement is controlled through a coordinate system that maintains operational simplicity.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If a single source substrate with fixed pattern is used, then the device structure is simple, but the system cannot produce different patterns, limiting versatility

Engineering Contradiction:

Improvesystem structure simplicityVSAvoidpattern diversity

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

Instead of using multiple source substrates with different fixed patterns, the system achieves pattern diversity by moving the receiving substrate during printing. This maintains simple device structure with a single source substrate while enabling versatile pattern production through controlled substrate movement and coordinate system transformations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A single source substrate serves multiple functions by enabling the production of different patterns through the movable receiving substrate. The same source substrate can generate various deposited patterns by adjusting the receiving substrate's position and movement, making the system universal and adaptable to different printing requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 flexible and precise pattern transfer without contact, allowing for adaptation of the source substrate pattern to match changing target locations on the receiving substrate, thereby improving throughput and accuracy in printing technologies.

Implementation Method 1

at least one laser scanner configured to illuminate with at least one laser beam a source substrate that comprises a plurality of trenches arranged in a first pattern and holding printing paste, wherein the source substrate is configured to release the printing paste from the trenches and onto a receiving substrate upon the illumination by the laser beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12337608B2Dynamic pattern transfer printing and pattern transfer sheets with spaced groups of trenches

Publication Date: 2025.06.24 WUHAN DR LASER TECH CORP LTD

AI summary

Dynamic pattern transfer printing systems and method are provided, which decouple the design of the trench patterns on a source substrate for pattern transfer printing, from the resulting metallic paste lines patterns transferred to a receiving substrate, such as PV cells. The receiving substrate may be moved forward (along the scanning direction of the laser illumination used to transfer the paste from the trenches onto the receiving substrate) to reduce the pattern pitch with respect to the source substrate, and/or the receiving substrate may be moved backward (against the scanning direction) to increase the pattern pitch with respect to the source substrate. For example, dynamic pattern transfer printing may be used to accommodate different widths of the substrates for more effective pattern transfer, and/or to enable one-to-many pattern transfer technologies with high wafer throughput. Also, pattern transfer sheet with separate multiple groups of trenches are provided.