Electrode Substrate Protective Layer Thickness Control

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Solution Overview

Problem

Existing methods for manufacturing electrode substrates with protective layers are inefficient in easily adjusting film thicknesses between different regions, leading to increased manufacturing costs and complexity due to the need for specialized photomasks and additional processing steps.

Innovation Solution

A method involving the application of a raw material liquid as droplets to form a protective layer with varying film thicknesses by controlling the application amount per unit area, allowing for a thinner protective layer in specific regions without the need for photolithography or etching, thereby simplifying the process and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If half-tone exposure technique with special photomask is used to form organic film pattern with stepped structure, then different film thicknesses between two regions can be achieved, but the number of process steps increases and manufacturing cost increases

Engineering Contradiction:

Improvefilm thickness adjustmentVSAvoidprocess steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention changes the application parameters of the protective layer by controlling the amount of raw material liquid applied per unit area in different regions. By varying the application amount (parameter), the film thickness is directly controlled without requiring complex photomask techniques, thus reducing process steps while achieving the desired film thickness differentiation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention extracts and eliminates the need for half-tone exposure technique and special photomasks from the manufacturing process. By using direct application control of raw material liquid, the complex photolithography steps are removed entirely, simplifying the process while maintaining the ability to achieve different film thicknesses in different regions.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

Engineering Contradiction:

Improvefilm thickness adjustmentVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces expensive special photomasks with a simpler, more economical direct application method. By controlling the application amount of raw material liquid through conventional means rather than requiring costly photomask fabrication, the manufacturing cost is reduced while still achieving precise film thickness control in different regions.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention uses parameter control (application amount per unit area) during the coating process itself to achieve film thickness differentiation, eliminating the need for expensive post-coating photolithography and etching steps. This parameter-based approach during material application is more cost-effective than the alternative photomask-based method.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional protective layer formation method is used, then uniform film thickness is achieved, but electrical stability in specific regions is compromised

Engineering Contradiction:

Improveelectrical stabilityVSAvoidfilm thickness variation

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention applies different film thicknesses in different regions of the electrode substrate according to local requirements. By making the protective layer thickness variable rather than uniform, the invention achieves optimal electrical stability in specific regions (such as peripheral regions) while maintaining appropriate protection in other areas, thus adapting the protective layer to local electrical stability needs.

Inventive Principle:

Principle #3Local quality

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 efficient and cost-effective formation of electrode substrates with tailored protective layer thicknesses, improving electrical stability and reducing the number of manufacturing steps, thus enhancing the electrical properties of the display apparatus.

Implementation Method 1

a step of forming a protective layer so as to cover the conductor pattern by applying a raw material liquid discharged as droplets to the first region and the second region of the first main surface of the first substrate

Methodology Applied

Scientific EffectDroplet deposition:

Data Source

PatentUS10126888B2Method of manufacturing electrode substrate, electrode substrate, display apparatus and input device

Publication Date: 2018.11.13 MAGNOLIA WHITE CORP

AI summary

A manufacturing process of an electrode substrate includes a step of forming a protective layer so as to cover a conductor pattern by applying raw material liquid discharged as droplets to an upper surface of a substrate in a first region and a second region of the upper surface of the substrate. At this time, an application amount of the raw material liquid per unit area in the second region is made smaller than an application amount of the raw material liquid per unit area in the first region, so that an average film thickness of the protective layer of a portion formed in the second region is made smaller than an average film thickness of the protective layer of a portion formed in the first region.