Film Touch Sensor Inorganic Passivation Layer Thickness Optimization
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Solution Overview
Problem
Current film touch sensors face challenges in meeting requirements for both transmittance and color value (b*), and existing manufacturing methods struggle with efficient stripping of inorganic materials, leading to incomplete removal and adhesion issues, while also lacking flexibility and heat resistance.
Innovation Solution
A film touch sensor design incorporating a separation layer formed on a carrier substrate, which can be used as a line-coating layer after separation, featuring a passivation layer made of inorganic material with controlled thickness and a protective layer with controlled elastic modulus to minimize cracking, allowing for high transmittance and suitable color values, and enabling the use of any film base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an inorganic stripping material is used, then the stripping process efficiency is improved, but the line and base are not efficiently stripped and portions remain on the substrate surface
Solution Approach 1:
The stripping material is divided into multiple layers with different functions: a first stripping material layer (inorganic) for initial stripping and a second stripping material layer (organic) for complete removal. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between stripping efficiency and completeness.
Solution Approach 2:
The patent uses a composite stripping material structure combining inorganic and organic materials. The inorganic layer provides efficient initial stripping while the organic layer ensures complete removal without residue. This composite approach leverages the advantages of both material types to achieve both high efficiency and complete stripping.
2Manufacturing precision
If organic stripping material is used, then complete stripping is achieved, but the material becomes stuck to the surface of the base and line
Solution Approach 1:
The stripping process is segmented into two stages: first using inorganic material for bulk removal, then using organic material for complete removal. This segmentation prevents the organic material from being the sole stripping agent, thereby reducing its tendency to adhere and leave residue on the surfaces.
Solution Approach 2:
The inorganic stripping material layer is applied first to perform preliminary stripping of the metal line and base from the substrate. This preliminary action reduces the amount of material that needs to be removed subsequently, allowing the organic layer to work more effectively without becoming stuck or leaving residue.
3Reliability
If multiple layers (insulating, transparent conductive, passivation) are present, then the touch sensor functionality is improved, but it becomes difficult to meet requirements for both transmittance and color value
Solution Approach 1:
The patent optimizes the thickness parameter of the passivation layer to specific ranges (50-120 nm, 220-290 nm, or 360-420 nm) to achieve the desired balance between functionality and optical properties. By precisely controlling this parameter, the multi-layer structure maintains both its protective function and acceptable transmittance characteristics.
4Strength
If the passivation layer thickness is increased, then protective functionality is improved, but transmittance decreases
Solution Approach 1:
The patent identifies specific thickness ranges for the passivation layer (50-120 nm, 220-290 nm, or 360-420 nm) where the protective functionality is sufficient while transmittance requirements are met. This parameter optimization resolves the contradiction by finding the optimal thickness values that balance both requirements.
Data Source
AI summary
Disclosed is a touch sensor, including a separation layer, an electrode pattern part formed on the separation layer and including at least one electrode pattern and an insulating layer, and a passivation layer formed of an inorganic material on the electrode pattern part, wherein the passivation layer has a thickness selected from among a thickness ranging from 50 nm to 120 nm, a thickness ranging from 220 nm to 290 nm, and a thickness ranging from 360 nm to 420 nm.