Flexible Touch Sensor Transfer Manufacturing
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Solution Overview
Problem
Current touch panel manufacturing processes result in rigid and costly touch sensors that are not suitable for flexible or curved displays, as they require high-temperature sputtering and lithography on stiff substrates like glass.
Innovation Solution
A manufacturing method involving a flexible touch sensing component with a nano-metal conductive layer, formed on a release layer, which allows for the removal of a temporary substrate, enabling the touch sensor to be transferred onto non-planar surfaces, and includes a bonding layer for direct adhesion to target substrates without additional adhesives, facilitating lightweight and thin touch panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature sputtering and lithography processes are used on glass substrates, then manufacturing precision and reliability are improved, but the touch panel becomes rigid, heavy, and expensive
Solution Approach 1:
The patent replaces traditional rigid glass substrates with flexible substrates (such as polyimide or PET films) and uses thin-film deposition techniques to create the touch sensing layers. This allows the touch panel to be lightweight and flexible while maintaining manufacturing precision through controlled thin-film formation processes.
Solution Approach 2:
The patent changes the substrate material parameters from rigid glass to flexible polymers, and modifies the manufacturing process parameters to use lower-temperature deposition methods suitable for flexible substrates. This enables the production of lightweight touch panels with maintained precision through parameter optimization.
2Manufacturing precision
If traditional sputtering processes are used on rigid substrates, then manufacturing precision is improved, but adaptability to flexible and curved surfaces deteriorates
Solution Approach 1:
The patent employs flexible substrates and thin-film structures that can conform to curved and non-planar surfaces. The thin-film nature allows the touch sensor to be bent and shaped while maintaining manufacturing precision through controlled deposition on the flexible base.
Solution Approach 2:
The patent creates a dynamic, flexible structure that can adapt to different surface geometries. The flexible substrate and thin-film layers can be dynamically shaped into curved configurations, enabling adaptability to various display forms while preserving manufacturing precision.
3Stability of the object's composition
If multiple layers and adhesives are used for touch sensor construction, then structural stability is improved, but the touch panel becomes thicker and more complex
Solution Approach 1:
The patent merges multiple functional layers into an integrated thin-film structure on a flexible substrate. The touch sensing electrodes, insulating layers, and conductive layers are combined in a multi-layer thin-film configuration that maintains structural stability while reducing overall complexity and thickness.
Solution Approach 2:
The patent uses composite material structures combining flexible substrate materials with thin-film conductive and insulating layers. This composite approach provides structural stability through material properties while keeping the overall structure thin and relatively simple.
4Manufacturing precision
If traditional manufacturing methods are used, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
The patent uses flexible substrates and thin-film deposition techniques that enable lower-cost manufacturing compared to traditional glass sputtering. The flexible substrate material costs are reduced, and the thin-film processes can be performed at lower temperatures, decreasing energy costs while maintaining precision.
Solution Approach 2:
The patent changes manufacturing parameters to use lower-temperature processes and alternative materials that reduce production costs. By optimizing deposition parameters and using cost-effective flexible substrate materials, the patent achieves manufacturing precision at lower cost points.
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
The method enables the production of lightweight, thin, and cost-effective touch panels suitable for flexible and curved displays, maintaining optical properties like high transmittance and allowing for electromagnetic interference shielding.
Implementation Method 1
a bonding layer for direct adhesion to target substrates without additional adhesives
Data Source
AI summary
A manufacturing method of touch sensors is provided. A flexible touch sensing component can be formed on a first substrate by a release layer. Next, the flexible touch sensing component is transferred to a second substrate after a releasing step. Furthermore, by the support of the second substrate, the flexible touch sensing component can be processed and then adhered a desired cover. After releasing the second substrate from the flexible touch sensing component, the touch sensor is formed.