Laser Scribing Transparent Conductive Layers Far-Side Ablation
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Solution Overview
Problem
Existing methods for manufacturing capacitive touch panels with projective capacitive touch technology face challenges in achieving high yield due to the need for multiple lasers and substrate manipulation, especially when creating different electrode patterns on both sides of the transparent substrate, which complicates the process and reduces efficiency.
Innovation Solution
A method involving two laser beams focused on opposing surfaces of a transparent substrate, with adjustable energy density and focal positions to enable simultaneous scribing of different patterns on each side without requiring a second laser or substrate rotation, utilizing far-side ablation to differentiate between the energy thresholds for each layer, thereby increasing the process window and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser is used with focal length changed to perform far-side ablation, then the need for substrate turning and second laser is eliminated, but the process window is reduced and yield decreases
Solution Approach 1:
The patent divides the single laser beam into two separate beams using a beam splitter. Each beam is independently focused to different depths - one beam focuses on the near-side surface while the other focuses on the far-side surface. This segmentation allows simultaneous near-side and far-side ablation with different focal positions, resolving the contradiction between simplified device structure and maintained manufacturing yield.
Solution Approach 2:
The patent introduces an additional spatial dimension by using a beam splitter to create two separate optical paths from a single laser source. This allows independent focal positioning for near-side and far-side ablation simultaneously, effectively adding a dimensional separation to the originally single-focus laser system.
2Use of energy by moving object
If near-side ablation is used, then laser power attenuation is minimized, but the ability to scribe different patterns on both layers is limited
Solution Approach 1:
The patent segments the single laser beam into two separate beams that can be independently focused at different depths. This allows one beam to perform near-side ablation with high energy efficiency while the other beam performs far-side ablation to create different patterns, thus resolving the contradiction between energy efficiency and pattern versatility.
Solution Approach 2:
The patent applies different focal positions to different regions of the substrate - near-side focusing for one pattern and far-side focusing for another pattern. This local differentiation of focal quality allows each region to be processed with the appropriate focusing mode, maintaining energy efficiency where needed while enabling pattern differentiation.
3Adaptability or versatility
If multiple lasers are used to scribe different patterns on both layers, then pattern versatility is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the functionality of two separate lasers into a single laser system using a beam splitter. The single laser source generates two separate beams that are independently focused to different depths, achieving the pattern differentiation capability of multiple lasers while maintaining the simplicity of a single laser source.
Solution Approach 2:
The single laser system with beam splitter achieves multi-functionality by simultaneously performing near-side ablation and far-side ablation with different focal positions. This universal system can create different patterns on both layers without requiring separate lasers for each function, reducing device complexity while maintaining versatility.
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 allows for higher yield and flexibility in creating distinct electrode patterns on both sides of the capacitive touch panels, even with thin substrates, by optimizing energy density and focal positions, thus simplifying the manufacturing process and improving efficiency.
Implementation Method 1
directing a first laser beam through one or more lenses to a focal spot on or closely adjacent to the first surface of the substrate
Implementation Method 2
directing a first laser beam through one or more lenses to a focal spot on or closely adjacent to the first surface of the substrate
Implementation Method 3
a transparent substrate has deposited on each of its opposite surfaces a layer of transparent electrically conducting material
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
The present application describes a method for laser scribing first and second transparent electrically conductive layers (14, 14') deposited on respective opposing first and second surfaces (12, 13) of a transparent substrate (11), the method comprising : directing a first laser beam (21) through one or more lenses (22) to a focal spot on or closely adjacent to the first surface (12) of the substrate (11), such that the focusing laser beam (21) passes through the second electrically conductive layer (14') and the second surface (13) of the substrate (11); initiating relative movement between the first laser beam (21) and the substrate (11) in two axes in a plane orthogonal to the axis of the first laser beam (21) to scribe a first pattern in the first electrically conductive layer (14); directing a second laser beam (21') through one or more lenses (22') to a focal spot on or closely adjacent to the second surface (13) of the substrate (11), such that the focusing laser beam (21') passes through the first electrically conductive layer (14) and the first surface (12) of the substrate (11), initiating relative movement between the second laser beam (21') and the substrate (11) in two axes in a plane orthogonal to the axis of the second laser beam (21') to scribe a second pattern in the second electrically conductive layer (14').