Laser Diode Mask Pinhole Pattern Fabrication
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Solution Overview
Problem
Conventional methods for fabricating micro patterns on display panels, such as lithography and high power CO2 laser processing, face challenges in precision and cost-effectiveness, particularly in achieving uniform micro phase retardation patterns with high contrast for large-sized and flexible displays.
Innovation Solution
A laser diode apparatus with a mask having a pin hole is used to focus light onto a laser absorption layer, which indirectly heats the material to form patterns, allowing for precise control of pattern width and intensity, and is applied in conjunction with a laser absorption layer on the display panel to prevent polarizer damage and enhance fabrication yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lithography is used to fabricate micro patterns, then manufacturing precision is improved, but device complexity and production cost increase due to the requirement of predetermined masks
Solution Approach 1:
The patent extracts and removes the mask component from the lithography system, replacing it with a maskless laser direct writing approach. The laser beam is directly modulated to write patterns without requiring physical masks, thereby eliminating mask-related complexity while maintaining manufacturing precision through digital control of the laser writing process
Solution Approach 2:
The patent replaces the mechanical mask system with an optical-digital control system. Instead of using physical masks that require alignment and handling, the invention uses digitally controlled laser beam modulation to define patterns, substituting mechanical components with optical and software-based solutions
2Productivity
If high power CO2 laser processing is used to fabricate patterns, then productivity is improved, but manufacturing precision deteriorates due to fine traces left between laser-scanning lines
Solution Approach 1:
The patent employs periodic scanning motion of the laser beam across the substrate with precisely controlled overlapping between adjacent scanning lines. By optimizing the scanning parameters and overlap ratio, the periodic action ensures uniform heating and eliminates gaps between lines, achieving both high productivity and uniform pattern quality
Solution Approach 2:
The patent changes key processing parameters including laser power, scanning speed, and line overlap distance to optimize the fabrication process. By adjusting these parameters, the system achieves complete pattern coverage without gaps while maintaining high processing speed and uniform pattern quality
3Ease of manufacture
If inkjet printing is used to apply patterns, then production cost is reduced, but reliability deteriorates because inkjet droplets are difficult to apply on some materials
Solution Approach 1:
The patent replaces the inkjet printing mechanical system with a laser-based thermal processing system. Instead of ejecting material droplets that have adhesion and compatibility issues, the invention uses laser energy to directly modify the substrate or apply and cure materials in situ, achieving reliable processing across diverse materials while maintaining cost-effectiveness
Solution Approach 2:
The patent utilizes phase transitions (such as melting, curing, or sintering) induced by laser heating to transform materials into desired patterns. This approach works reliably across different material types by controlling the thermal process, avoiding the material compatibility limitations of inkjet printing
4Manufacturing precision
If CO2 laser heating treatment is used to form micro phase retardation patterns, then manufacturing precision is improved, but use of energy increases due to high power requirement (about 100 Watt)
Solution Approach 1:
The patent introduces a laser absorption layer as an intermediary between the laser source and the phase retardation film. This intermediate layer absorbs laser energy efficiently and converts it to heat, which then transfers to the phase retardation film. This mediator approach allows the use of lower power laser diodes while achieving the same thermal effect, reducing energy consumption while maintaining precision
Solution Approach 2:
The patent changes the wavelength parameter of the laser source to match the absorption characteristics of the laser absorption layer. By selecting a wavelength that is strongly absorbed by the intermediary layer, the system achieves efficient energy transfer with lower input power, reducing overall energy consumption while maintaining uniform heating and pattern 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
The solution enables the production of micro phase retardation films with uniform distribution and high contrast, reducing production time and costs while improving the quality of large-sized displays, particularly for 3D LCDs, by using a low power laser diode array and a mask with a pin hole to control light intensity and pattern width.
Implementation Method 1
at least one laser diode, at least one lens and a mask having at least one pin hole, wherein light emitted from the laser diode is through the lens and the pin hole to be focused on a first material layer
Implementation Method 2
light emitted from the laser diode is through the lens and the pin hole to be focused on a first material layer
Data Source
AI summary
An apparatus for fabricating patterns using a laser diode is presented. The apparatus includes at least one laser diode, at least one lens and a mask having at least one pin hole, wherein light emitted from the laser diode is emitted through the lens and the pin hole to be focused on a first material layer.