Etching Plate Stepped Intaglio Pattern for Window Lamination
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Solution Overview
Problem
Existing window fabrication methods face challenges in preventing the removal of printed pattern layers during the lamination process, leading to defects and increased defect rates, especially in the outer bezel area, and may result in voids due to the steep angles formed between printed pattern layers.
Innovation Solution
An etching plate with a stepped intaglio pattern, including first and second intaglio pattern portions of varying depths and widths, and a third intaglio pattern portion inclined at an angle, is used to charge and transfer printing ink onto a base substrate, forming printed pattern layers with varying thicknesses to overlap the bezel areas, reducing the defect rate and preventing voids during lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-depth intaglio pattern is used for printing, then the manufacturing process is simple, but the printed pattern layer cannot prevent removal during lamination and creates voids due to steep angles
Solution Approach 1:
The etching plate is divided into multiple intaglio pattern portions with different depths (first, second, and third portions) to create multi-layered printed pattern layers with different thicknesses. This segmentation allows each layer to serve specific functions: thicker layers provide rigidity and prevent removal, while thinner layers maintain flexibility, collectively preventing void formation and pattern removal during lamination.
Solution Approach 2:
Different regions of the etching plate are given different local qualities through varying intaglio depths. The first intaglio pattern portion has a first depth for the inner bezel area, the second has a second depth for the outer bezel area, and the third has a third depth for intermediate regions. This local differentiation optimizes the printed pattern layer properties in each specific region to prevent removal and void formation.
2Ease of manufacture
If a steep angle is formed between printed pattern layers, then the etching process is simpler, but voids occur during lamination
Solution Approach 1:
The etching plate design incorporates dynamic angle control where the third intaglio pattern portion is inclined at a controlled angle between the first and second portions. This creates a gradual transition in layer thickness that dynamically adjusts the interface angle during lamination, preventing void formation while maintaining etching process simplicity through a single-step inclined etching method.
3Loss of substance
If the printed pattern layer is made thinner to reduce material, then production cost decreases, but the layer becomes too flexible and may detach during lamination
Solution Approach 1:
The printed pattern layer is constructed as a composite structure with multiple intaglio pattern portions of different depths, creating layers of varying thicknesses. The first and second portions create thicker layers for rigidity and detachment prevention, while the third portion creates thinner layers for material efficiency. This composite approach optimizes both material usage and structural strength.
Data Source
AI summary
An etching plate includes a first intaglio pattern portion spaced apart from an edge portion of the etching plate and having a first depth, and a second intaglio pattern portion adjacent to the first intaglio pattern portion, and having a second depth greater than the first depth of the first intaglio pattern portion.